Well I haven't got much further actually Steve as I'm waiting to get a shed up at home so I have somewhere to do the work. Nearly there finally.
I did manage to get my hands on the original engine block about a month ago. Long story but until recently it was basically still in the same workshop where the car was maintained in the 70's. It ended up in an Escort rally car with pushrods and a pre-crossflow Cortina head on it. It's approx 89mm bore so nearly 2 litres.
It's a special casting with a boss added on the oil gallery for an external oil feed. Alloy blocks are the same because there isn't enough room for the oil gallery to run through the engine with the bigger bore. They were totally bored out and the liners were vacuum brazed in. This is how you got 2 litres out of a BDA engine before alloy blocks were thought of.
I need to get it crack tested to see if it's useable and it will need a bore if it is as it's scored in No3. A nice bit of work actually and really pleased to have it.
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