I have been planning a 2.0 build for a long time. I've done my homework, know what I need to do and what I need to get.
My recipe is 2.0, custom mounts, do the harness myself, buy TT aluminum radiator, use the 1.6 bellhousing, and the RingR with the 71-74 celica clutch to a w56 with dual cases, toyota axles, yj springs, FJ60/80 box, 20" stretch, frame and tub.
What I have is the axles, springs 1 tcase and I JUST picked up an Aerio 2.0 liter (I may have to run a sidekick trans/tcase until I can afford the ringr and dual tcase adapters)
On my shopping list was a custom flywheel for the 1.6 bellhousing on the 2.0. Then I had the brilliant idea that the 1.8 from the sport/esteem may have just what I needed.
I don't know exactly the differences in the 1.6, 1.8 and 2.0 flywheels. I also don't know what custom machining is done to make the 1.6 flywheel work with the 2.0. I do know that TT charges $150 to do it! So after searching and searching, everyone says you need a custom flywheel, and so far everyone I know that has done the swap has used a custom flywheel. I also found that the 1.8 sport uses a hydraulic clutch, just like the 2.0, so it has a different bellhousing. So I figured my idea was shot to shit. However I did see one man who had mated a 1.8 to a stock 1.6 transmission without modifications. I have seen him mention it in several threads. He is a very reputable source. Mr. Eric Bewley

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The 2.0 swap into the x would also require all the hyrd clutch gear, so not only the bellhouseing but the whole assembly. on the plus side you would get to lose the distributor and belt.

Are you sure? I've bolted a 1.8 DOHC which is essentially the same as a 2.0 DOHC to a 1.6 transmission. It was a direct bolt up. Same clutch was used (cable actuated from the 1.6 transmission).

I may have misread due to there being so many questions and subsequent discussions off of the initial post.

Anyway, HTH -Eric

So this leaves me wanting to find a 1.8 flywheel just to try it! I asked Brent at TT, and he said the 1.8 flywheel is the same as the 2.0 and that I need a 1.6 flywheel and get it custom machined.

SO MY QUESTION IS: Does anyone have pics of these individual flywheels for comparison? Has anyone used this flywheel the way I intend to? (2.0-->1.6)
Thanks,
Clancy

Someone on here did the conversion a year or two ago, they just machined up a bush for the flywheel. I can't remember their username though.

yeah I recall for the w56 with the ringr the clutch and  pilot bearing need to be machined and either the throwout bearing or snout it rides on to be machined. But for just straight forward, 1.6/16v transmission, I don't think anything needs to be machined, except perhaps the flywheel itself. I'm hoping using the 1.8 flywheel will eliminate the need for custom flywheel machining.

Nobody has any input on this? I guess I'm on my own.

You will need a redrilled 1.6 flywheel to use the mechanical bell housing. That's all that the TT one is. Or use the complete hydraulic bell and add a clutch master cyl.

The 1.6 and 1.8/2.0's have a different  crank bolt pattern. And the 2.0 flywheel is too thick to use in the 1.6 mechanical bell. Hope this answers your questions.

Yeah, pretty much. I had done some research and compared a leftover 1.3 flywheel to the 2.0 flexplate I have. I met someone local to me that machined his own flywheel for the 2.0 swap, and yeah its just drilling the holes, and opening up the center bore. So I'm looking for a 1.6 flywheel and bellhousing, clutchfork and arm. Luckily these are usually leftovers from 1.6 samurai swaps, so someone around here should have one molding behind their shop. I'm going over to my buddy's shop friday, hopefully I'll find one growing green stuff there.
Thanks.