Snyth, I think I have 2 spare heater cores, you are welcome to one of them. If it is just a crack it would be just as well to repair it, but if yours is corroded through it should be replaced.
The welder only charged $100 for welding both flywheels, I paid him with cash to get a "discount". He is quite a skilled welder. So we have $50 into each flywheel so far.
I went to the Arlington pull-a-part today and found both an '84 Tecel4wd and a Corolla all-trac. So I spend WAY more time than I had intended there today. I pulled the all-trac tank and the tercel tank to inspect them side by side. It looks like it will fit, they were almost exactly the same shape, so I bought the all-trac tank with the pump and sender in it. It was $22.50 for all three. The All-Trac tank is several gallons bigger I think, it is two inches wider but that did not look like a problem, at worst the Tercel muffler heat shield will have to moved over about an inch.
There will be some adaptation to make them work: the whole assembly needs to be swapped end for end and the securing straps have to be reversed too. But they are located in exactly the same place so the tercel mounting system and location will work perfectly. The fuel pump has to be pulled and reinstalled so the fuel lines face forward, that is the easy one. The tank is held in place by two metal straps that force it up against rubber pads at certain locations, including the bottom of the spare tire well. Since the spare tire well are the same size it fits there perfectly. There is a mount against the floor of the Tercel that is unneeded for the All-trac tank. It may interfere with the fuel lines, so it has to be hammered flat or cut off.
The biggest issue is the filler neck, the Tercel tank has it coming off the right front side on top, and the All-Trac tank, when oriented so it will fit, has it coming off the right rear top. Both have bolt on flanges, so it appears all we have to do is cut a hole in the right spot and mount the Tercel filler neck, and make a blanking plate for the old filler neck location. If the angle is off (which it might be) I think using a short length of rubber hose with large clamps will work fine. the Tercel already uses a short length of rubber hose on it to give the neck some flex, but it does not appear quite enough, so a longer length should do it. It might even be possible to get a long flexible rubber hose and go from the Tercel filler cap location to the current All-Trac tank inlet location, there appears to be enough room. The hose would make a larger "S" bend. I will have to consider each option when the time comes, but either is a viable. The most important issue of course is it must not leak, so I am tempted just to use the factory filler location. But a long curing rubber hose could be vulnerable to chafing and developing leaks. I will take apart the filler neck and get a closer look at the flange later, with enough sealant and a thick rubber gasket I think it will hold up fine. The sender wire connector has four wires, and the Tercel has three, so I do not know if this will be an issue or not. We might have to switch senders if we use the All-Track tank, and the mounting hole is a different size and has a different number of screws in it. Though the All-Trac sender might be made to work with the Tercel fuel gauge.
It appears it is possible to make a larger hole in the top of the stock Tercel tank and mount the internal pump. Presuming there is no baffles or other internal interference. Either way there will be some cutting and sealing and always a risk of a leak. The easiest way is to just use the stock tank with an external pump, a fuel pump at pull-a-part is only about $9. and there are plenty of cars that use external EFI pumps.
As for clutches, these are the only performance clutches I have found that fit the early Tercel flywheel.
http://cabrera.stores.yahoo.net/
http://www.specclutch.com/cars/Toyota/T ... 984/Single
The first one offer only their lowest "hp" performance clutch for the early Tercel it is a good price for $159. SPEC clutch ofter stage one, two and three clutches for the early Tercel for $239, $299 and $329. I thought when the time comes I would call both of them and see which one is better. I suspect the SPEC clutch is going to be more durable and might be worth the money, but If the Cabrera clutch has the same power rating than it might be a bargain.
Another thing I did at the Pull-a-part was try different front brakes on the Tercel. The corolla vented disk and caliper fit, but require shimming the disk out about 0.2". The '91-'92 Tercel (which also has vented disks) appears to swap right over with no shimming, I installed one caliper and disk right on to the '84 Tercel (it is still on it in fact). You have to switch left and right calipers since the hoses mount differently, or you can switch to the banjo type end on the brake line (which means buying new brake lines). I could not find any disk brakes for the rear, there were no MR2 or GTs there to try. Interestingly the Corolla caliper appeared dimensionally similar to the later Tercel caliper, but they were different assembly.
If anyone is interest in the Tercel at the Arlington pull-a-part, this is what I found: It is a DX, so it has the plastic seats (which were trashed), it is missing the hood and right front fender, but the bumpers, doors and rear hatch were there. It is light yellow, an automatic, and the head and intake/exhaust/carb were gone, as is most of the front trim, grill and lights. The gas tank is out, but I left it there.
The All-Trac is mostly complete with front end damage to the hood, radiator and grill. All mechanicals look good, it is the 4 door, not the wagon. But the rear axle assembly is there, and this can be adapted to the Tercel, it has the much heavier axles and diff, and it has 4.1:1 ratio (I was considering snagging it for my conversion). LSD rear ends are available to fit this heavier rear axle but this one did not have an LSD in it (I checked, it was a factory option). Interestingly the rear brake drums are the same as on the Tercel. The fuel tank and fuel pump are gone of course.
