how to get the most power from 1.6L MK2 Escort

IIRC you can fit the pistons out of the 1.3 into the 1.6 block to raise the CR, bit of porting on the head, bigger valves, bigger cam (Kent 234 or similar wouldn't go any wilder) and a stock 32/36 carb should see over 100hp with a good rolling road setup IIRC. Not played with crossflows for years.

Yip as the other guy says best bet fit the 2 litre pinto cheap power, really depends on what you want from it or as I'm doing at the mo redtop on bike carbs awesome power and still easy to drive

Belive me tuning the crosflow is not cheap. As far as i know all 1.6s came with a twin choke weber and a four branch manifold anyway, so if yours has lost these that would be a first step. And yes 1.3 pistons will up the compression ratio but obviously its an engine strip to fit them, and if your stripping it then you might as well change the camshaft, if you go for anything wilder than a Kent 234 you will need to machine the pistons to avoid the valves hitting them. All this will probably get you 110BHP if set up properly which is about the same as a standard 2 litre pinto. The crosflow is much lighter than the pinto however. But if you do as popuptoaster sugests you would have the beefed up front legs to cope with the extra weight.

Aah I just noticed your in Oz, I guess that puts a different spin on things if the trusty ol' 2 litre is hard to find.

I know you have rules about what you can and can't swop over there, maybe go through the list and see whats allowed and what you can find cheap that easy to fit.

Either way, tuning a N/A motor almost always works out more expensive than swopping in a bigger one, i'd wait and get the bits together for a swop but if you must tune it read this.

www.burtonpower.com/tuning-guides/tuning-guide-pages/ford-kent-crossflow-tuning-guide.html

Turbo- or supercharging an engine is always cheaper than trying to get more power from it in NA form.
Perhaps you could use the 1.3 bottom end with 1.6 head and compound charge it;)

the engine and box will be ok but the suspension on the cortina is no good for your escort

If you just have a standard 1.3 escort then the gearbox is abit naff tbh. If you drive it hard with a tuned 1.6 then it will pop in no time. Like yourself i started out with a standard 1.1 crossflow engine. I managed to get hold of a 1.6 711 block, brought new pistons which are relatively cheap and a BCF2 cam. I used a 32/34 weber carb and it ran ok. I've now got a 4 branch exhaust and trying to fit bike carbs which are being a pain but should be worth it. A couple of things to look at though is if you fit bike carbs then if you have the old servo tower then you will have to swap this for ether a bias box or singe unservoed master and if you have a standard shell then without modifications no other gearboxes fit straight in.

This is a good read
www.burtonpower.com/tuning-guides/ford-cars/Ford-Escort-Mk1-Mk2-Tuning.html

and this is good tuning guide for the crossflow
www.burtonpower.com/tuning-guides/tuning-guide-pages/ford-kent-crossflow-tuning-guide.html

If you go the 2ltr route you will also need an RS2000 sump and oil pick up pipe (or modify the steel sump with a BIG hammer). There are other things to consider as well such as the exhaust is on the other side and of course the carb so the fuel lines need to be switched round. don't bother with the escort box, you may as well use the 5 speed type 9 that normally comes with the pinto engine. there are other things that need tweeking but its an easy swop and its been done many times so should you have any problems there is always someone to help