Mk2 Cortina 1600E Crossflow Engine Reconditioning

[Rockerrob666]

love this thread, getting a close inspection view of a full works being done, and done right! really learning a lot here, loving it! keep it up dude

[blacksofstichill]

Well i would like to say something.................but, i am lost for words, great update yet again

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(shurrapp Sid)

 

 

Cheers!

 

love this thread, getting a close inspection view of a full works being done, and done right! really learning a lot here, loving it! keep it up dude

 

Thanks, glad you're finding it interesting, it's not often many people get the chance to see a full job like this being done, glad you like it all so far.

[hicksy]

I love the updates on these threads!

 

Keep up the good work!

[Georgio]

All that workmanship...quality.Kind of school there,really interesting.I can't wait the first time she fires up.

[blacksofstichill]

I love the updates on these threads!

 

Keep up the good work!

 

Thanks, really appreciate your interest in it.

 

All that workmanship...quality.Kind of school there,really interesting.I can't wait the first time she fires up.

 

Thanks, I'm really looking forward to hearing it fire up too!

 

Cylinder Head given it's 1st coat of engine enamel -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0349.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0350.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0351.jpg

 

And after another coat, the difference is hard to see on the photos but is really noticeable in the metal, I also gave the block a 3rd coat at this point -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0352.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0353.jpg

 

Close up of the finish on the block -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0354.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0355.jpg

 

Engine Mounts fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0356.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0357.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0358.jpg

 

 

Pushrods ready to fit -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0359.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0360.jpg

 

Rocker shaft cleaned and ready to fit -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0361.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0362.jpg

 

Setting the valve clearances, these were miles out having done so much reworking of the head and valves. Inlet Valves are set to 0.012" using feeler gauge -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0363.jpg

 

Exhaust Valves are set to 0.022" so I use the 10 and 12 thou feeler gauges togther -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0364.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0365.jpg

 

Valve Clearances all set -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0366.jpg

[Georgio]

Very good.It's coming to an end slowly...

[sidrick]

Superb forumming.

[blacksofstichill]

Cheers guys, really appreciate it!

 

Onto the rocker cover, here it is as it was when I got it -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0367.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0368.jpg

 

And after a bit of cleaning it was back to bare metal -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0369.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0370.jpg

 

One coat of Zinc Primer -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0371.jpg

 

And after 2 coats of regular primer -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0372.jpg

 

While that was drying I moved onto the flywheel, here it is as supplied -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0373.jpg

 

Cleaned up with the wire brush on the drill -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0374.jpg

 

Onto the Centre Lathe -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0375.jpg

 

Face cleaned up -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0376.jpg

 

Back to the Rocker Cover, here it is after 3 coats of gloss black -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0377.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0378.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0379.jpg

 

On the head, you might have noticed I'd painted the spark plugs, these were just old ones I fitted to stop paint from going down the plug holes -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0380.jpg

 

Old ones out and the ones it came with were cleaned up and fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0381.jpg

 

New Rocker Cover Gasket fitted -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0382.jpg

 

Rocker Cover screwed down -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0383.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0384.jpg

 

Almost there now!

[ganges]

yet another great update...............but was begining to think you had got stalled of working, been waiting for ages for another update

[blacksofstichill]

Thanks, yeah, although the work had been done I've been short of time to update things, getting caught up now though!

 

I then spent some time touching up any chipped paint and giving it all a dust down before it comes off the stand -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0385.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0386.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0387.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0388.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0389.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0390.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0391.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0392.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0393.jpg

 

Then it was time to take it off the stand and put it back onto the wooden base -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0394.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0395.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0396.jpg

 

Ports, etc taped up to prevent dirt, etc getting into them -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0397.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0398.jpg

 

And that's it all finished, I'll keep it under cover here to keep it mint until it's time for collection -

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0399.jpg

 

http://blackengineering.co.uk/images/Mk2-Cortina-1600E-Crossflow-Engine-Reconditioning/0400.jpg

 

It's been a cracking project this and I've really enjoyed it, thanks to everyone who's taken the time to read through it and comment, etc, much appreciated.

[Georgio]

yet another great update...............but was begining to think you had got stalled of working, been waiting for ages for another update

 

Thought that also.Fortunatelly this didn't happen.Time is an issue for all of us these days...

 

That is really a new engine mate,well done.Nice practice regarding spark plugs threading.Nice work on the rocker cover too.Just a question.Did you paint the interior of the cover?Won't it peel off due to temperatures and oil etc etc?I always thought that I would like to paint it too,but the thinking of flaking pieces of paint finding their way to the sump changed my mind.

[blacksofstichill]

Thanks, yeah, it's pretty much a split new engine now!

 

I cleaned the inside of the rocker cover but I didn't paint it, only the outside of it was painted.

[Georgio]

It looks really clean,it's like freshly painted.

[blacksofstichill]

I just had a look at the photos and I see what you mean, that's the original paint coating on the inside just cleaned up by me, it does look as good as new in there though, you're right.

[Hencca]

Hi,

What an amazing tutorial!  How many hours did you spend on this reconditioning?

 

Cheers,

Henric