I knew that I would need a different exhaust. Individual mandrel bends are fairly expensive, but I stumbled on these Jegs weld up header kits. That's stupid cheap for the number of bends you get! It's aluminized mild steel, but I'm not exactly worried about this lasting forever.
Luckily the ports are round, so a 2-1/2" x 14" x 1/2" piece of 1018 cold rolled steel was ordered which fit perfectly. Bi-metal hole saws make quick work of the flange, and a couple good weekends with the welder produced the majority of a header:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20141007_20_14_53_Pro_1.jpg)
The ignition coil is from a Ford Escort.
Next piece was a cooling pipe to get from the back of the head to the Tercel radiator. I bought a 6' stick of 1" SCH10 stainless pipe from ebay and went to town:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20141122_14_47_51_Pro.jpg)
I didn't want to sped the money for a bunch of els, so all of the corners are 45° miters. Not the greatest for flow, but considering the opening on the thermostat I wasn't worried about it.
The last thing built before going into the car was an alternator bracket that was integrated into the coil bracket:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20141009_20_59_52_Pro.jpg)
Next step, out with the old!
After installing a pilot bearing, clutch, freshly surfaced flywheel, and swapping the Tercel oil pan, the 5A was put into the engine bay... And already the problems started to show:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150131_11_54_55_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150131_11_55_05_Pro.jpg)
That's not gonna work at all...
![Sad :(](./images/smilies/icon_sad.gif)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150406_21_49_22_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150406_21_49_34_Pro.jpg)
Hood sits on the oil cap and still isn't closed, doh!
Oh well. While deciding what to do, I added a 5/16" pickup to the fuel tank for the fuel pump from a '76 Celica.
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150201_12_08_23_Pro.jpg)
The fitting is a 90°-05 JIC bulkhead elbow. On the inside of the tank is a tube with a strainer on the bottom. I didn't trust the factory 1/4" pickup tube to feed the carb pump, so I went bigger. All of the fittings are JB-Welded together to prevent leaks.
Running under the car is a 5/16" aluminum tube that's bent to run with the factory fuel lines.
That all runs up to a surge tank in the engine bay that feeds an EFI pump.
Anyway. Back to the intake!
At this point, I decided to build something custom. So some 1/4" 1018 steel was ordered and a flange made:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150223_17_43_45_Pro.jpg)
Sadly the intake ports are not round, so I drilled out to a reasonable size and then finished everything out with a carbide burr:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150223_19_34_24_Pro.jpg)
At this point I'd also been working on the other half of the cooling system. The stock thermostat housing didn't fit between the head and the firewall, so I decided to move it. I made matching blank off plates for the head and the housing, and moved it to the side of the block:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150221_16_42_22_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150222_17_06_25_Pro.jpg)
The heater was connected and a bypass to allow hot coolant from the head to flow around the thermostat was tee'd in:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150228_16_40_50_Pro.jpg)
More bits of exhaust tubing were used to make the intake. The runners are 1.5" exhaust pipe x 11" long and the plenum is 3" exhaust pipe:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150314_13_34_55_Pro.jpg)
The ends of the runners were formed (read: hammered) to match the ports on the flange, and a burr was used after everything was welded to blend it all in.
After some throttle fitment issues, it was decided to move the surge tank under the intake and route the throttle toward the washer tank:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150314_18_18_24_Pro.jpg)
A little time with the MIG later and we have the bulk of the intake!
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150315_14_18_09_Pro.jpg)
To get the throttle cable over to the throttle, I used part of the Corolla throttle cable housing that came with the engine, an 8 mmx1.25 coupling nut, and a section of 2mm stainless wire rope.
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150315_15_13_06_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150315_15_13_12_Pro.jpg)
The cable ends are cut up shanks of 1/4" bolts about 3/8" long with a 3/32" hole through the center. Get everything lined up right and zap it with the MIG running stainless wire to get a super nice custom throttle cable.
On to finishing up the exhaust:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150329_17_05_25_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150329_13_22_38_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150329_17_08_50_Pro.jpg)
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150329_17_06_31_Pro.jpg)
Bought a 180 and a 180 + 45 mandrel bend in 2" pipe on ebay, plus bought a couple lengths of straight pipe locally. Muffler is a Walker turbo muffler I bought on Rock Auto, the cat is something I bought on ebay for cheap. The flanges are from Rock Auto as well. They take some care to get them set up right, but boy are they nice to have for pulling the exhaust apart.
Which leads us to the current state:
![Image](http://i37.photobucket.com/albums/e66/Teranfirbt2/WP_20150406_21_15_03_Pro.jpg)
Made some things pretty, finished up the fuel and cooling systems, and pretty much got everything locked in.
Ditched the Ford coil pack for a Hyundai Accent pack. It's got the correct terminals for the factory Tercel wires, and is still a 3 wire coil. Probably doesn't have the oomph of the Ford pack, but I don't really need it for a 5A.
(And yes Peter, the intake has a brace back to the motor mount bracket
![Wink ;)](./images/smilies/icon_wink.gif)
The last major hurdles are wiring and the hood issue, stayed tuned!