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Custom Builds

If you want to keep the stock capacity of your bike then we have four package types available…

–          Head Only
–          Trail
–          Offroad
–          High Performance

The Head Only, Trail and Offroad packages are suitable for all riders and are just as reliable as a stock bike, yet offer increased performance over stock.

The High Performance packages are suited to serious racers or people who really want the most from their engines but who are also willing to go through the tuning and ongoing maintenance that a modified engine can need. These engine are definitely not time bombs or ‘on the edge’ but they do take more care and attention to maintain than engines of lower performance. If you are willing to take this responsibility onboard then the rewards can be HUGE!

Please see our Mods Explained page for a more detailed description of each individual mod or service offered in these packages.

Please note that engine capacity makes very little difference to price as the same processes are involved in modifying an 80cc engine or a 500cc engine.

 

HEAD ONLY
Our Head Only setups involve correcting the squish clearance, setting the compression ratio and adjusting the combustion chamber shape to suit local conditions. Sometimes this is all you need to turn your bike into a weapon (or a tractor, depending on your needs). One thing is for certain though, setting up the head correctly is a MUST HAVE mod for any two stroke. It is easily the best bang for your buck mod and will make a very noticeable difference to almost any current model bike. The benefits can include more stable jetting, much better detonation resistance, better fuel economy and more power (usually felt most in the bottom end and midrange but we can aim for more top end on many bikes). Our Head Only setups have been used by everyone from average-joe trailriders through to National and World Champs. Don’t be fooled by many aftermarket bolt on heads that still have the wrong compression ratio for our fuels, poor squish clearance and often cost more.

 

Head Only Mods Description Price

Performance Head Design

We check dimensions and measure the volume of your stock head, design a new profile using our professional software and then machine the final design on a lathe or CNC mill depending on the type of head. The final design will have the correct squish clearance and compression ratio for your application and will offer dramatic improvements in performance, more stable jetting, reduced risk of detonation and improved fuel economy. We can usually tailor these designs to suit Bottom, Mid or Top power delivery. Some heads require welding to add extra material before machining. Does not include labour to remove refit/head or measure current squish clearance.

 

$240

$55 extra if welding reqd.

Budget Head Machining

(some KTM 200/250/300 EXC models only)

Usually it’s a big mistake to just cut the head without reshaping the combustion chamber but some KTM models can get away with this safely. By taking the right amount of material off we can correct the squish clearance and compression ratio in one hit. We are still confident that our Performance Head Designs are better overall but if you want a simple and cost effective head setup this will still work very well. Does not include labour to remove refit/head or measure current squish clearance. $150

 

 

 

TRAIL
Our Trail packages are simple, cost effective setups that maximise bottom end and midrange power and cater to the budget conscious rider. Aside from providing the same great benefits of a properly setup head we also machine the cylinder base to add extra bottom end grunt. This simple mod shifts the whole powercurve lower in the rpm range and makes the bike easier to ride in a range of conditions. This is a great mod to do if you are racing an MX bike offroad and need a broader spread of power but want to keep costs to a minimum. Some bikes that particularly benefit from the extra bottom end this mod gives are 05+ CR250’s and TM250/300’s, although it can be done to almost any bike to give more bottom end pull.

 

 

Trail Package Mods Benefits Price

Performance Head Design
+
Machine Cyl Base

Much better bottom end and midrange, many bikes retain same or similar top end. Proper head design makes jetting much easier, significantly reduces risk of detonation and can improve fuel economy. Does not include powervalve strip, clean and rebuild, labour to remove/refit parts or labour to measure current squish clearance. $330

 

Suggested Extras

Powervalve strip, clean and rebuild
Carb Oval Bore (adds mid/top)
Top end rebuild labour
Top and bottom rebuild labour
Dyno tuning/jetting
Piston kit, gaskets for top end rebuild
Crank bearings, seals, parts for bottom end
$90
$220
$300-$400 approx
$700-$800 approx
$300-$500
$150-$300 (eg 250cc usually ~$240)
$ ask for quote

 

 

 

OFFROAD
Our Offroad packages are higher performance than our Trail packages and suit everyone from the average trail rider through to serious racers. They use the same great head designs combined with our Standard Cylinder Porting to improve power throughout the rpm range by making the absolute most of the stock cylinder design. All casting flaws are removed, the cylinder base is matched to the base gasket and cases (on some models), the intake and exhaust ducts are smoothed and shaped, the port windows are carefully cleaned up and the powervalve components matched to the exhaust duct. Depending upon the power delivery required these setups may also involve machining the cylinder base to get the ports in the right spot or the use of epoxy to increase bottom end and throttle response. There is virtually no risk to reliability with these packages and the gains are very noticeable. We offer two choices of powerband with our Offroad packages… you can have Maximum Bottom End or Broad Power, with Broad Power being our personal favourite as it gives more everywhere on most stock engines.

 

 

Offroad Package Mods Description Price

Performance Head Design
+
Standard Cylinder Porting
+
Machine Cyl Base (when needed)

Choice of power delivery. Offers more power everywhere, maximises the stock design potential, more stable jetting, reduced risk of detonation, better fuel economy. Really transforms most stock bikes. Keeps the basics of the original cylinder design. Does not include powervalve strip, clean and rebuild, labour to remove/refit parts or labour to measure current squish clearance. $440 – $550

 

Suggested Extras: V Force reed cagePowervalve strip, clean and rebuild

Carb Oval Bore (adds mid/top)

SX Ignition (KTM EXC’s only)

Specialist Top end rebuild labour

Specialist Top and bottom rebuild labour

Dyno tuning/jetting

Piston kit, gaskets for top end rebuild

Crank bearings, seals, parts for bottom end

$195$90

$220

$330

$300-$400 approx

$700-$800 approx

$300-$500

$150-$300 (eg 250cc usually ~$240)

$ ask for quote

 

 

 

HIGH PERFORMANCE

Our High Performance engine packages offer the maximum performance we are able to provide while maintaining good reliability. We can tailor the power delivery to suit your needs, however in most cases we try to give the broadest power spread possible as that is usually the key to a fast engine on the track. These packages combine our Performance Head Design with our Advanced Porting plus any other extras you choose. These builds involve setting up the head to suit your needs, measuring and assessing the potential of the stock port layout, designing porting changes using professional level software, modifying ports to match the new design, removing casting flaws, smoothing, shaping and modifying the intake, transfer and exhaust ducts, modifying the powervalve and matching the cylinder base to the cases. Results of this work can be MASSIVE and can totally transform an engine from bottom to top. We strongly suggest that these builds be combined with Dyno Tuning and other key extras such a V Force reed cage, carb mods and Ceramic Thermal Barrier Coatings to ensure maximum performance from the setup. Due to the nature of high performance engines the customer must have a reasonable understanding of jetting and be willing to keep up regular maintenance. Once these engines leave our workshop the customer is responsible for maintaining a safe state or tune as weather and riding conditions change.

 

High Performance Package Mods Description Price

Performance Head Design

+

Advanced Cylinder Porting

+

Machine Cyl Base (when needed)

Choice of power delivery. Offers more power everywhere, maximises the stock design potential, more stable jetting, reduced risk of detonation, better fuel economy. Really transforms most stock bikes. Keeps the basics of the original cylinder design. Does not include powervalve strip, clean and rebuild, labour to remove/refit parts or labour to measure current squish clearance. $570 – $680

 

Suggested Extras: V Force reed cagePowervalve strip, clean and rebuild

Carb Oval Bore (adds mid/top)

SX Ignition (KTM EXC’s only)

Digital Programmable Ignition

Ceramic Thermal Barrier Coatings

Lectron Carburetor

Crank Balancing

Specialist Top end rebuild labour

Specialist Top and bottom rebuild labour

Dyno tuning/jetting

Piston kit, gaskets for top end rebuild

Crank bearings, seals, parts for bottom end

$195$90

$220

$330

$390 (fitting and tuning extra)

$65 per part

$550 (fitting and tuning extra)

$POA

$300-$400 approx

$700-$800 approx

$300-$500

$150-$300 (eg 250cc usually ~$240)

$ ask for quote