Weeeell, a Friday afternoon & home early from work. Push out the car & get the Zetec ready!
I was obviously having another of my "bad engineering days" when everything I do goes wrong, but after a struggle I have the stronger ARP bolts on the engine's big ends, & the new sump in place, the clutch is torqued up, so it's ready to go in the car.
I've had a measure up & surprisingly it's actually smaller than the crossflow - in terms of envelope size - that is it's slightly shorter in hieght & length & not as wide, although is is much boxier, so it fills the space envelope more. I still think getting it all under the bonnet is going to be a chellenge.