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The problem is that trying to do it with CF is the only thing possible because SD would be way too slow at the NES clock speed. Having a faster clock is possible with an extra CPU on the card, and it would be a lot less complexity overall. Probably drop the cost of the cart to sub-$99, and the guts ...

I had this total nutjob idea involving a NES and an AVR wired up to the cart port.

Emulating the hardware either on a PC or with a NOAC results in something that isn't quite a NES and doesn't quite play games correctly, but why couldn't you emulate the cartridge itself?

The idea I have in mind ...

The NES connector uses 0.1" (2.54mm) spacing doesn't it? One can buy 72 pin 0.1" card edge sockets. That's save a lot of time lining up and gluing and whatnot. I don't know about getting one that you could crimp a ribbon cable on to, but that should be doable too.

Just an idea.

I think a mass-produced version should allow the cart to be pushed down.

In fact, if I were refitting a toaster, I'd want to install a leaf switch or something that would make the thing fail to operate until you did so.