Yep, I agree, OB. I have no idea why erle would think all the expense of an aftermarket big bore unit would be less than what the factory would/might charge, and especially considering if one doesn't have the mechanical expertise to do it themselves, what the additional labor charges are to have an aftermarket mechanic do the job for them, AND considering that the line workers at the factory don't get any extra pay depending upon what cylinder heads and cranks are being assembled into an engine while the motorcycle is being manufactured.
My guess would be similar to yours here and using your Sportster example as a comparison. I would think Triumph could manufacture both a standard 865cc and a larger displacement model on the same factory line, and could still make money on the larger displacement model by adding no more than a $2,000 premium.
And from what I've heard from some of those around here who haven't done their big bores to their own bikes and have had to have a mechanic do it for them, the total cost of their project was a lot more than 2 Grand.
