Bob,
It doesn't sound like you checked your block for
straightness. Yes it is possible for the block to
warp, or maybe some important metal got rusted away.
One very cheap test that is very usefull is the compression
test. workable compression meters only cost $30 (or less)
and it can tell you loads about what is going on.
I would have saved myself a couple hundred dollars this summer
had I done a compression test on the cortina before I took
it in to get it tuned up on the dyno. It had a very slight
miss, I never would have guessed that I had no compression on
cylinder #4.
lrc
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