you're usually better off picking up a new heatercore. They are usually dirt cheap; like us$20 for a brand new, shiny, leak-free one instead of us$20 for a used, gunky, slimy, questionable one you had to pull out of some junked car yourself.
I'll let someone else talk about diminishing returns vs. size and flow order, but in short: bigger is usually better, but only to a certain point where it becomes less than worth your while. A lot of people like pump>heatercore because it takes any heat the pump may have put into the water out before circulating it to the blocks. It has also been generally concluded that flow order doesn't matter much, so do whatever gives you the shortest flow.
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Abit NF7-S ... xp1800+ ... Abit GF4ti4200 ... Maxtor 120gb SATA150
Currently gathering parts to water cool everything! ( read about the project)
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