Mk2 Cortina V8 Build.

RobW · 09-04-2021, 02:43 PM

Hello everyone, Looks like I'm finally starting on my Cortina project. I'm expecting it will take a while and I thought I'd start a thread here to try and keep all my upcoming questions in one place, and maybe others might be half-interested in what I'm doing.

I'm looking to make a 100% street-legal cruiser (QLD). By my calculations I can go as high as 3.6L so the Rover is a natural choice. A 221 v8 would have been nice (just to keep it Ford) but they're, shall we say, rare.

I already have a Rover 3.5 from a P6 which is the shortest variation and has a front bowl sump, which will be the easiest to fit.

So far to make it compliant my jobs to do are:

1) Brakes will be need to be upgraded to a dual-circuit and a booster fitted (looking for suggestions on master cylinder and booster).
2) Move battery to boot (clearance).
3) Enlarge tunnel to fit gearbox, if necessary (clearance).
4) Fabricate engine/box mounts.
5) Fabricate exhaust (I'm thinking of reversing P5 exhaust manifolds to exit at the front cylinders and go from there).
6) Fit retractable front seat-belts.
7) Dual wing mirrors.

The car has a collapsible steering column from factory so that's covered. I'm hoping to not have to do a rack and pinion conversion, if I do it's only for room.

I have a BW35 currently behind the Rover, which realistically needs a rebuild, so I'm open to suggestion of other boxes which might fit the tight space and the Rover. I'm contemplating a v8 Trimatic and Dellow bellhousing, as the BW45 bellhousing is quite large. It will be a cruiser, the car is already an auto and I want to keep the stock interior, and an auto will be kinder on the diff.

As it's only a little v8 and I have a light foot I'm keeping the stock BW diff for now, and I'm hoping to keep my 13" rims. To do that I think I want to upgrade the wheel studs. Is it possible to upgrade the studs in strength of metal as opposed to physical size (just so I can keep my stock rims)?

The aim is to make the conversion look as factory as possible, and not attract too much attention.

I know there's a few of these conversions around - has anyone here done one?

Cheers,
Rob.

LG17 · 09-04-2021, 03:07 PM

I'm not sure you'll be able to keep the 13" wheels as you will need a decent brake package and not just dual circuit and booster.
Have you thought of a Triumph Stag manual box, although probably very hard to find here?

Sar4890 · 09-04-2021, 08:05 PM

If like you say you are not going to beat on it wouldn't a freshened up BW35 still be Ok?

RobW · 09-04-2021, 08:16 PM

Quote:

Originally Posted by Sar4890

If like you say you are not going to beat on it wouldn't a freshened up BW35 still be Ok?

Yes the BW35 will do just fine - I'm just looking to see if there's an alternative with a shorter bellhousing to help with the fit - but I'm guessing I'll have to do some cutting regardless.

LG17: Yes I may have to go further than just dual-circuit and booster but the engineer is willing to consider it for now.

RobW · 21-04-2021, 05:51 PM

Well the under dash brake unit costs over $2.5k, so I guess I have to find another solution!

**Captain Stubing** · 25-04-2021, 10:24 PM

Here’s the answer to the easiest question.... wheel studs! I got these to extend the studs on my Sierra, but went to 17” rims to house larger brakes.

gassed250 · 21-05-2022, 02:28 AM

Sounds interesting
Wilwood do an MC that bolts to the firewall, there's no way to get a booster on the firewall or in the engine bay and still have enough room for the engine and there's no room under the dash, however you can use a pair of remote boosters and fit them in the boot

Brakes would definitely need an upgrade, I have a pair of rebuilt gt struts that have large vented rotors and 4 piston calipers

The little borg warner diff will have a hard time dealing with anything that resembles torque
And are.you sure it has a collapsible column ?

RobW · 21-05-2022, 09:48 AM

Hya, The build has progressed slowly due to 'life' stuff. I'm now putting an RN20 diff under the bum and GT discs up front with a 5 stud conversion to match the rear using zephyr hubs. Brakes will be dual circuit, with a remote booster for the front...that's the plan but I'm open to advice. I've got most of the bits, I'm just working through reconditioning them one by one. I haven't decided on as master cylinder yet but I think the willwood will be a good choice. My Cortina is one of the last
MK2's built and has the 10A compliance code denoting a collapsible column (my understanding that's what the code is for).

gassed250 · 21-05-2022, 06:40 PM

Yeah things seem to take forever when life gets in the way, Ive been slowly building a mk2 2 door
Mine has a supercharged Ford 3.8 v6, 5 speed manual, shortened M78 from an EL Xr6
Front brakes are VE commodore/AU falcon and EL discs on the rear but I still have the 4x108 pcd, Wilwood master and dual remote boosters in the boot

I had to make a collapsible column so I modified a Toyota Yaris Epas column, not really a big deal as i had to change it anyway as the vehicle now has a rack front end

RobW · 21-05-2022, 07:09 PM

Wow that looks like quite a build! How are you going to get a supercharged 3.8 passed the new national guidelines if you don't mind me asking? Or is it still registered lol?

gassed250 · 21-05-2022, 07:49 PM

Quote:

Originally Posted by RobW

Wow that looks like quite a build! How are you going to get a supercharged 3.8 passed the new national guidelines if you don't mind me asking? Or is it still registered lol?

New guidelines ???
When did they change ?

Its not registered, however the engineer that I've been dealing with is happy with whats been done

RobW · 21-05-2022, 08:36 PM

They're not that new - I think they came in 2011, the National Code of Practice for light vehicle construction/modification. Basically they have a kerb weight to capacity ratio that puts max supercharged capacity for a Mk2 Cortina at about 2.5L. That's why I'm going with a Rover v8 because max NA capacity is a shade under 3.7L. But if you have an engineer on board who's happy and going to pass it, keep him happy and I'm sure it'll be roses - didn't mean to alarm you! Whereabouts are you based?

gassed250 · 21-05-2022, 09:11 PM

Ok
Same old vsb14 that's been around since Jesus was a boy

RobW · 22-05-2022, 10:20 AM

I haven't read the Bible, but I though Jesus was older than that.....?

chappy60 · 22-05-2022, 04:35 PM

we have a club member here in QLD that has a
351 in it and legal heaps of mods went into the
build to do it though

RobW · 22-05-2022, 05:56 PM

Quote:

Originally Posted by chappy60

we have a club member here in QLD that has a
351 in it and legal heaps of mods went into the
build to do it though

Really? Every engineer I've spoken too has been 100% firm on the capacity (regardless of modifications). I'd love to have a chat to him if he's available?

gassed250 · 23-05-2022, 10:22 PM

Quote:

Originally Posted by chappy60

we have a club member here in QLD that has a
351 in it and legal heaps of mods went into the
build to do it though

I know of a few Windsor mk2's and 1 with a 2jz currently in the build

RobW · 24-05-2022, 08:45 AM

Are the windsors old builds or current? If they're current I'd REALLY like to chat to their engineer - I'd much rather a windsor! 1jz fits within the LA1 formula, but I want a v8, not horsepower lmfao.

RobW · 24-05-2022, 02:41 PM

Quote:

Originally Posted by RobW

Are the windsors old builds or current? If they're current I'd REALLY like to chat to their engineer - I'd much rather a windsor! 1jz fits within the LA1 formula, but I want a v8, not horsepower lmfao.

*2jz sorry.

gassed250 · 27-05-2022, 08:43 PM

Quote:

Originally Posted by RobW

*2jz sorry.

It's a 2jzgte
They are all new builds, I have no idea who their engineers are

RobW · 28-05-2022, 08:15 AM

Well next time you see them, please ask I'd love to know. I've had similar conversations outside the forums....It seems everyone knows someone who's building a v8 Cortina, but can never put me in touch with their engineer.....

pcman · 29-05-2022, 06:11 PM

didnt the mk2 have a 1.6l engine, and curb weight of 857kg, according to vsb14 that means a 6.4l is possible, being 4x stock capacity ?

RobW · 29-05-2022, 09:06 PM

Quote:

Originally Posted by pcman

didnt the mk2 have a 1.6l engine, and curb weight of 857kg, according to vsb14 that means a 6.4l is possible, being 4x stock capacity ?

Nah it's multiplying kerb weight x 4 = capacity. Not multiply capacity by 4.

LA1 states between 800kg/1100kg it's kerb weight of heaviest sedan variant x 4 (for NA) = CC max capacity. 857kgx4= 3.428L.
I've got the 1600L@922kgx4=3.68L

That's how I understand it.....?

simon varley · 30-05-2022, 10:49 AM

is there any logic or engineering behind that sum at all? why is kerb weight even related to engine cc?

RobW · 30-05-2022, 11:21 AM

Quote:

Originally Posted by simon varley

is there any logic or engineering behind that sum at all? why is kerb weight even related to engine cc?

I assume that it's to have a rough power-to-weight scale for the lowest common denominator to grasp. Logic and legislation rarely go together.....but that's what it is.

gassed250 · 21-06-2022, 09:21 AM

Quote:

Originally Posted by simon varley

is there any logic or engineering behind that sum at all? why is kerb weight even related to engine cc?

No logic what so ever and this is why some engineers will allow engines that are outside the "recommended" capacity

We can legally fit a 2.3 ecoboost that makes more power than a 351
The V6 that I'm using has 170kw (less than most modern 4 cyls) and weighs less than a 2.0 pinto but doesn't fit in the the recommended capacity