Which external 800k drive do you have? Is it the one that also works with the IIgs (It has an eject button that doesn't do anything when connected to a Mac) or the slimmer Mac specific one? The latter won't boot a 128k or 512k with the original ROMs. Assuming it is the IIgs one, on the other hand, that one is a "universal replacement" and will behave like a 400k external unless...
The A9M0106, commonly used with the IIgs, will boot an 800K MFS disk on a Mac 512K.
Note that if you WERE to upgrade your Mac to 512k to work with the HD20 you'd still be limited to system... 4.2? unless you do the ROM swap to make it a 512Ke, in which case it will run System 6, very poorly.
Apple kept supplying 64K ROM patches through System file version 4.1. But you can copy the patches into newer system files to regain support for the 512K. A stock Mac 512K can in fact run System 6, but you need the right patches in it.
If one upgrades a 128 with Plus ROMs, do the extra HFS/HD20 routines still use extra RAM?
They still use the low-memory globals and have their system heap data structures for Drive queue, etc. But because HFS and the improved Sony disk driver are in the 128K ROM, they won't be loaded into RAM on any system that has this ROM. That check is done at boot time in the System file.
If the 128k has 128k of RAM, it will not work with the HD20.
Not strictly true. There's a check in the System file that can be NOP'd. One other change is needed too, and then it will load on a Mac 128K with 64K ROM. But it won't be very useful, because it'll take up about 32K of RAM, leaving you with something like 60K or so for running an application.
Even with Plus ROMs installed (which effectively creates a "512Ke" with only 128k of RAM) I don't think you can use an HD20 on a 128k Mac. Maybe someone here has tried it and can prove me wrong but I don't think there's enough RAM to effectively run any software once the overhead of the HD is added. (As I recall the one reason to make a 128ke was to add limited 800k floppy support.)
You
can use a Hard Disk 20 on a Mac 128Ke, that is, a Mac with 128K of RAM and the 128K ROM. I did it, and have a screenshot from a Mac 128Ke with an HD20 mounted, towards the end of my
Hard Disk 20 article. This configuration fully supports the Hard Disk 20, HFS, and double-sided disks.