So, the sense line is figured out, it just needs to be pulled to ground. What it does is tell the Sharp to listen for data as the tape is running. If that sense line is floating then it won't do a thing.
Essentially it's this switch here on the cassette deck:
IMG20240211151339.jpg
Any time any key is pressed, so play, record, ffwd, rwd, this switch is made, pulling sense to ground. In fact the only time it isn't pressed is when the deck is stopped. So I connected pin 2 (ext read) to pin 8 (int read) and pin 1 (ext write) to pin 7 (Int write) so that the external inputs will work.
Since the sense line cannot be made when you execute the LOAD command (I don't know why, probably the sense input being out of order in the load sequence) I still required a switch in order for it to activate at the correct moment.
Well, it turns out that I have just that in the old internal cassette module. All I needed to do was do the ext to internal bodge wires underneath the mainboard, then connect up the old cassette unit and press play on that when I want to load from the external cassette interface.
EDIT: It turns out that LOAD does work at the monitor does load with the sense line connected to ground all the time, so I will likely return at a later date, disconnect the internal cassette completely and just tie pin 5 of the connector to ground permanently.
I verified this here:
MZ-700 repairs.
So, does it work? Yes it does, here we can see it's loading Snake & Snake:
IMG20240211143402.jpg
And the final result:
IMG20240211143723.jpg
That's a result I'm happy with for sure.
Next thing I need to pull the keyboard apart, but will do that another day, as the cursor key cluster doesn't seem to be working, though everything else is.
I am going to see if I can find a replacement head for the internal cassette unit, and I need to see if I can find WAV files of the cassettes as so far Snake & Snake is all I can load!! So as yet no BASIC, but the tape does seem erratic during playback.
I will also try my other cassette deck to see if loading improves with that.