The old engine was hoisted out. Some of the parts from this engine can and will be used on the new engine.
(April 2014)

Used 9" rear bakes were found in serviceable condition and will be used.

A gear box was dissected and a few parts will be shipped for cutting new cogs.
This will result in a close gear ratio gear box with arelatively high first gear, but tightly spaced second, third and fouth gears.

A set of 4,44:1 rear axle cogs were acquired. The tyres will be low profile, and the speed will hopefully be a bit higher, so a higher ratio than before will be used.

The block is bored out to close to 1600 cc. Afterwards the bores are honed to the correct piston clearance.

Here the piston protrusion is measured. The top dead center is found with a dial indicator, and the amount the pistons were under the deck was measured with a flat machined piece of metal and a feeler gauge.
The pistons were 0,10 mm (.004") under the deck at the number 1 cylinder and 0,15 mm (.006") at the fourth. As the block is cut to the right piston protrusion, the deck will be cut square at the same time.

The connecting rods were weighed and balanced to about 0,1 grams using an automotive paint mixing scale.

The decision to use a new cylinder head was made due to the fact that the head gasket blew twice in the same spot, and further, as the compression ratio would have gone ridiculous with the larger displacement of the new engine.

In this pic new bigger valve seats are cut for large valves.

K-line valve guide inserts are mounted in the old bored out valve guides.

The crank shaft along with the crank pulley, fly wheel and clutch pressure plate are balanced to tight tolerances.

The serviceable brakes above were of a design not approved for a Cortina GT, so a "new" pair of sorry looking but right design brakes were found after a few phone calls. These will be used with new drums.

New wheels for the 2014 season. These will improve the looks of the car considerably.

The limited slip differential started slipping last season and was then dismantled. After lying around the shop for half a year all parts were washed and lubed, and the LSD shimmed back to specs.
The new gears were also installed and the back lash adjusted.

The new rear brakes. Media blasted and painted backing plates with new brake cylinders and -linings. New brake lines too. And wheel bearings & gaskets.

A nice load of parts came from Jeppo Racingfactory today:
www.bnmotor.fi
and
www.anorrback.fi
Ported, cc:d and flowtested cylinder head, balanced rotating assembly, bored, honed and decked block.
Pic shows the block being decked.

New modified drums came from Tuovila Speedrparts ( J. Louko). Drums are Escort items, turned down to fit the narrower Cortina brake shoes and half axles.

Secret measurements and performance calculations being done at BNMotor.

Hint: Has to do with piston protrusion, compression volume and the like.

All piston rings were tried in the bores and the ring clearance measured. Then they were mounted on the balanced pistons, all within 0,1 gram (.003 oz), and mated to the connecting rods, which were balanced to the same tolerance.
The pistons were put into the washed and lubed bores, and all main and big end bearings were checked with plastigauge.
(May 2014)

After determining exactly at which point Top Dead Center is on the crank pulley, the new camshaft was degreed according to the cam card, which stated that the intake lifter/pushrod should lift 2,6 mm +-0,15 mm @ TDC.

After some filing and checking, adjusting and rechecking, the cam was degreed correctly.
These Ford engines has a locating dowel, and as its hole was filed, the cam shaft and sprocket were located by drilling a hole into the shaft through the sprocket and nailing in a roll pin (arrow). The sprocket mounting bolts will do the rest of the job.

The result of a days work. Every part of the engine, so far, have been assembled, checked and disassembled a ridiculous amount of times, but at least I'm sure everything is ok.
The pushrods hit the rockers when opening the valves fully. Luckily this was discovered at this time, and could be remedied by grinding the pushrods a bit. All this resulting in two rocker shafts being mounted, and valve lash adjusted at least five times.
Time-consuming, but the idea is to make sure the engine goes together correctly the first time.

Another day and the engine is in the car. The ignition is timed, the splash plates in the oilpan had to be altered to fit the oil pick up of the new engine, all the electricals, but the battery, are done, as are the coolant hoses and radiator, oil pressure gauge, starter etc.

Getting there...
The Cortina needs to be ready by saturday 10:th (the day after tomorrow), as then it's time for the FIA test at the MOT test facility. The FIA passport has to be renewed, and the Cortina is going into a new category.
Carbs and exhaust done here, as is the rear axle with drive shafts, oil, brakes, lines bled etc.

With a test drive completed a couple days ago, some tweaks done today, and the Cortina loaded on a rented trailer, we're on our way to the FIA check-up.
(May 10 2014)

Here we are at the MOT test facility, where the FIA check up was done for the new FIA passport.
The new category is G/A Group 2 (1966-1970, over 1300 cc, Touring cars). The roll cage was measured, the casting numbers of the cylinder block and head were checked, as were the carbs, the type of brakes, suspension, swaybars and shock absorbers...

Now 4", 5" 5½", 6" and 7" wide weels may be used, as opposed to only 4" last season.

All other things aside, this is the all-important FIA hologram sticker, stuck to the roll cage. I had to make do without it last season after painting over it in the winter , the old one was in front of the windscreen, but at long last it's there again.

New wheels for the 2014 season.
The centersection and spokes are painted a glossy silver, and the rim is polished. The plain steelies are also painted silver, and are meant to be used as spares.
Yokohama tires will be used, much wider ones than the Dunlops used last season on 3 ½" and 4" rims.
(Still May 2014)

A hose down after a successful drive on dirt roads with rally tires in the rear. The engine really seems to have a bit more bite than the old 1200.

With the new wider wheels on nice polished and painted wheels, the Cortina looks heaps better than last season on skinny wheels and tires.
Only one minor problem: The rear wheels have too little back spacing so the tyre hits the wheel opening and gets stuck...

Only solution is other wheels. Borrowed blue wheels. Why does blue follow this project all the time???
The wheels look awful, but then again, function has to go before looks. Hopefully someone will take pity in me, and offer better looking wheels for sale.