Millyard Kawasaki S1 Four Cylinder Crankcases - How Its Made

Millyard Kawasaki S1 Four Cylinder Crankcases - How Its Made - Episode 1

Рет қаралды 392,074

Күн бұрын

In this video I show how I converted a pair of kawasaki S1 250 crankcases from 3 cylinder to four cylinder and fitted Kawasaki S3 400 barrels making the engine around 550cc with +0.5mm pistons. The process is carried out in my home workshop and shed using mainly hand tools and a 1950's vintage milling machine and my TIG welder which is a 15 year old 240V, 200A, DC/AC machine, and I use 5% silicone filler wire for welding cast aluminium. Tracey cooks some Oatmeal Cookies and Charlie Weaver helps in a supervisory capacity, in between his tipples of coarse!
This video was filmed and edited using my iPhone 11 Pro.
Hope you enjoy the video
Best Regards
Allen

Пікірлер: 1 100

@gasdive 2 жыл бұрын

I still can't really believe this can be done. It's so obviously impossible. Yet you make it look easy. Just perfect.

@barrymartin3813 2 жыл бұрын

And with a 2nd hand blade, amazing

@dozer1642 2 жыл бұрын

It actually is impossible for mere mortals, but for Allen, it’s just a thing.

@robertjarmai2627 2 жыл бұрын

This is pure magic.

@ossanyberg 2 жыл бұрын

@@barrymartin3813 The Sandvik blades last forever. Mine is 40 years old.

@jonasasterlund 2 жыл бұрын

indeed, and i still can't believe this is also done without a single curse word. inconceivable

@carleddison7479 2 жыл бұрын

"...this is where I'm going to cut them with my hacksaw..."!!! This man is an engineering genius. Incredible talent.

@alexmorgan3435 2 жыл бұрын

I go into my garage, gaze at all my tools, hacksaws, files, hammers and welder. I think of Allen. Then decide nah ............ another day and go back inside in the warm. He's a genius.

@zorktxandnand3774 2 жыл бұрын

No bike is ever made with the correct number of cylinders, according to Allen. But a very good video once again, always lots to learn from the master. Looking forward to the rest of the build.

@daveb7663 2 жыл бұрын

Come for the fabrication, stay for the baked goods.

@GodmanchesterGoblin 2 жыл бұрын

I put it down to the N+1 rule. The ideal number of anything that you have (bikes, cameras, games consoles, cylinders in a bike engine, etc.) is always at least N+1 where N is the number currently available.

@philw4053 2 жыл бұрын

@@GodmanchesterGoblin This is so true! However I'm very thankful for this natural law otherwise we wouldn't have Alan doing his stuff...

@TibianoUru 2 жыл бұрын

6 was the perfect to me . Sound of 6 cilinders are so good

@paulhewson4600 2 жыл бұрын

@@daveb7663 Right,,,,always wondering whats goin on in the Kitchen,,,and he's so skinny,,,,

@juanmcmahon7765 2 жыл бұрын

We need a Nobel Prize for Mechanics here ... Incredible skill!

@olih27 2 жыл бұрын

Amazing level of accuracy performing those cuts with a hacksaw

@rogermckenzie2711 2 жыл бұрын

Us mortals are still in awe!

@PillSharks 2 жыл бұрын

Gets me every time I watch! unreal how accurate he is isn’t it.

@victorpelini5995 2 жыл бұрын

Wait till you see him aligning the crank dead straight with a copper hammer on first try.

@rogermckenzie2711 2 жыл бұрын

@@victorpelini5995 But he couldn't do it without Tracey's cooking! She's a star too.

@victorpelini5995 2 жыл бұрын

@@rogermckenzie2711 yeah, these videos are so relaxing

@leonsutanta6409 2 жыл бұрын

While everyone else convert their ICE vehicle to electric, Allen converts 3 cylinder engine to a 4 cylinder. What a legend!! We need more people like Allen.Thanks for sharing this video,Allen

@shawngoldsberry747 2 жыл бұрын

Electic vehicles run on coal

@gamemeister27 11 ай бұрын

@@shawngoldsberry747Natural gas mostly in the US, but we're doing better than ever with renewables.

@tomthompson7400 2 жыл бұрын

A rare Sunday treat , way better than Top Gear. A master class in how its done , it looks almost like its a follow along video , I bet theres a sudden shortage of S1 engines starting tomorrow, if the rest of the series is as detailed and clear , this could be a great project . Many thanks.

@fishyfool 2 жыл бұрын

I don't know, making straight cuts with a hacksaw is beyond a lot of guys I know...

@ParaBellum2024 2 жыл бұрын

@@fishyfool First there'll be a shortage of S1 engines, and then there'll be a glut of crankcases that have been hacksawed part-way through, sent for scrap!

@AllenMillyard 2 жыл бұрын

all being well the crank video will be up next Sunday

@stanleydenning 2 жыл бұрын

@@fishyfool That's why you use a bandsaw.

@kriswright1022 2 жыл бұрын

@@stanleydenning Never seen him use one, ever.

@lawrencekeating5571 2 жыл бұрын

Modern custom builders: CNC machines, CAD, crews of highly trained professionals. Alan: I’ll trump you with my old hacksaw and a handful of files. Plus a few home made goodies from the missus. Alan - your knowledge and skill blow me away every time I watch one of your videos. I feel like I’ve just watched a modern day wizard at work 👍👍

@Byzmax 2 жыл бұрын

The reason why he makes it look so easy is ....... Because he knows what he is doing and understands how to solve problems. Superb as always Allen.

@dukiemoto8676 2 жыл бұрын

If you are a lover of motorcycles, engineering, fabrication, the sound and smells of petrol with snippets of nature and sweet confectionery, well then Sir Allen Millyard is your man and this channel is for you. God bless our world treasures.

@BibtheBoulder 2 жыл бұрын

Millyard, RyanF9, and TMF on a live-feed...what a weekend...!!!

@bunkie2100 2 жыл бұрын

“I hope you enjoyed the video”. Not to worry, Alan, we adore them. From your lovely calm, happy demeanor to your almost superhuman fabrication skills to your love of your wife’s fabulous baked goods, your videos satify on so many levels.

@47MasoN47 2 жыл бұрын

I've been working on getting 2 old Honda CB550s running (nearly got 1 there), one of them had the threads for the drain plug on the oil pan stripped out. I managed to make a mess of drilling the hole out and tapping it to M14. It astounds me how you're able to just hack these engines apart and weld them together again like it's no big deal. You're an incredibly talented fellow!

@fishyfool 2 жыл бұрын

He's a rocket surgeon! If you do a little research on Allen, you'll find he's not your everyday garden variety engineer.

@Doug791 2 жыл бұрын

@@fishyfool rocket surgeon or brain scientist ? Wouldn't surprise me if he's both.

@davidelliott5843 2 жыл бұрын

Allen is 3D thinker extraordinaire.

@robertwoodliff2536 2 жыл бұрын

It's like everything.,practice makes perfect.......he did the things that went wrong decades back.........now he knows..So the plug went skew .,it won't go skew next time..But then Allen says its perfect.,but of course that is relative.,it built to a standard that will run.,as was the original..It's within the limit and fits..What I find very impressive is putting weld into a structure that was never welded.,I'd be tempted to glue it.,there are some very impressive glues out of people like 3M..

@senatorjosephmccarthy2720 2 жыл бұрын

@@robertwoodliff2536 , and West System.

@harezy 2 жыл бұрын

14:25 Like the three bears.. Someones has been drinking you're tea!! 😁😁 Amazing engineering

@AllenMillyard 2 жыл бұрын

hmm I noticed that in the edit 🙈

@TurbodanNM 2 жыл бұрын

I will never tire of these videos.

@kasperkjrsgaard1447 2 жыл бұрын

“Harry’s Garage” at dinnertime and “Millyard’s Shed” at bedtime. 😃👌 This is just perfect. I’m well pleased with that.

@kennywallace1 2 жыл бұрын

On the off-chance it hasn’t been said already some merch with “Fits Perfect” and “Well pleased with that” needs to be made. I marvel at your creations made in that shed.

@malcolmtill 2 жыл бұрын

Click on His name above then STORE and you will find what you seek

@kennywallace1 2 жыл бұрын

@@malcolmtill Thanks, didn’t know about that.

@eliotmansfield 2 жыл бұрын

‘and you get there in the end’

@jonnycando 2 жыл бұрын

He gets an idea….he takes a hacksaw…..and the idea becomes a thing! I so can’t do that but what I have found out is that when I am building an engine….sometimes…..it just feels right….and it works!

@mastercylinder1939 2 жыл бұрын

Tracy really spoils you, a master baker and a master engine builder under the same roof.

@paulhall170 2 жыл бұрын

CGI? What's CGI? Allen does all that complicated stuff for real, in real time, and has time for a tea and a cookie. You never cease to amaze us, sir. Thank you again for allowing us into your incredible world.

@DifferentRides 2 жыл бұрын

Best motorcycle engineering DIY (not) Channel of all times! There are "bike builders" and there's Allen, a complete different level!

@tam1381 2 жыл бұрын

I can almost guarantee the next episode will include. Birds, hedgehog, cookies and the famous BBQ . Which will be just perfect. Wonderful video Allen. Top Man.

@twentyrothmans7308 2 жыл бұрын

I've been watching Garage 54 cut a four cylinder Lada engine in half to create a two cylinder model. Allen adds cylinders and doesn't shout and yell as much as they do. Perhaps it is edited out. Oh, and Allen is a genius.

@leifvejby8023 2 жыл бұрын

Not always adding cylindres, he also built a twin from some left over bits - left overs from some sawn apart three cylindred ones.

@joseywales3789 2 жыл бұрын

Allen, *"Just Great!"* Charlie Weaver, the Barbecue, Tracey's baking, I missed the Swiss Army Knife but you made up for it in spades with the awesome Engineering, Master of the hacksaw and draw file! Thank You for sharing this with us. Enjoyable and Educational. 👍👍✌✊

@johnmfjw 2 жыл бұрын

I had an idea that the Barbacue would make an appearance.

@markrigg7038 2 жыл бұрын

Totally amazing work, I have trouble cutting down a bolt 🤣

@stephenthompson6049 2 жыл бұрын

Real engineering at its best, with a dollop of humour, wildlife and baking thrown in, what’s not to like??? We are not worthy lol

@tca375 2 жыл бұрын

Amazing work with just basic tools for the most part.

@jeffzekas 2 жыл бұрын

Watching Alan reminds me of why the English invented some of the greatest technology ever known to the world, and created many of the modern inventions that made our civilization what it is.

@trevormj 2 жыл бұрын

Some of the best english engineers were Scottish...

@Shane-zx4ps 2 жыл бұрын

@@trevormj. Best invention ever was the radar.

@gavind9487 2 жыл бұрын

@@Shane-zx4ps I'd go with the wheel

@doctordapp 2 жыл бұрын

Got my peanuts and a beer.... Time to pause Netflix for the important and interesting stuff! I'm 100% interested in the crankshaft steps... Have one to do for my own project!

@Jones-xx2gc 2 жыл бұрын

Not word for word, but found these two engines lying around in my shed. Just cut them in half and make a four cylinder engine, like you do, and you do it with a hacksaw. Brilliant. By the way Tracy needs to wright a cook book.

@jannemec4567 Жыл бұрын

I can watch this series over and over. It's just perfect

@michaelarchangel1163 2 жыл бұрын

As always, brilliant work and very therapeutic viewing. I chuckled at Allen for describing Tracey's spatula as a stick. Keep this man from kitchen duties, to avoid visits to A&E with throat splinters.

@animalian01 2 жыл бұрын

A great,great episode. When I was an apprentice I spent endless hours learning to use a hack saw and files correctly,and can honestly say your technique is impeccable. The cookies were impeccable as well both of you are masters of your art.

@Doug791 2 жыл бұрын

Anyone can make an engine , but cookies..... 😂😂

@danmanthe9335 2 жыл бұрын

"...then my wife brought out tea and a cookie and my priorities instantly changed." The correct way to live life

@seankearney6915 2 жыл бұрын

@@danmanthe9335 I thought it deserved more than a single cookie though. At least one per cylinder.

@tomthompson7400 2 жыл бұрын

aac ?

@animalian01 2 жыл бұрын

@@tomthompson7400🤔

@fromgermany271 2 жыл бұрын

She does not only bake you some nice cookies, she also allows you to play with your big boy‘s toys and does not even complain (hard enough) about using the grill as a kind of forge. I hope you every day praise the rare situation you are in. 😎😎😎

@ronhuffman7973 2 жыл бұрын

Thanks Allen! Enjoy watching you demonstrate your skills!

@richardhall9687 2 жыл бұрын

I absolutely love this guy's presentation. To the point, no fluff, and the bits about real life (pinching the wife's bakery) are so relatable. Oh, and he apparently knows a thing or two about machines.

@Banditmanuk 2 жыл бұрын

An absolute highlight when I get an Allen Millyard notification. An amazing demonstration of skills. Thank you and look forward to the next episode

@Ralph2 2 жыл бұрын

Quite simply extraordinary.

@Mr-ue2ul 2 жыл бұрын

Perfect. Top gear just finished. Now for the real top gear

@fergavilan132 2 жыл бұрын

Hi Allen, we are a couple of mechanic and electronic engineers with many years of experience in the automotive industry, magister in quality and many more, and still pretty hard to believe that somebody could have such enormous skills to do something like that. We are more than astonished and want to congrat for your magnific job, keep doing what you love and will live forever! Regards from Argentina.

@AllenMillyard 2 жыл бұрын

Thankyou

@rockypup1968 2 жыл бұрын

You can tell how good an engineer Alan is , as he makes it look easy ..

@mikelefevre1701 2 жыл бұрын

Absolutely fantastic episode as always. Trouble is u make me want to retire and mess with bikes full time!

@nickrider5220 2 жыл бұрын

I just couldn't do that, I can strip and rebuild engines, modify them a wee bit...but this is so many levels beyond me ! And that hacksawing, wow !!

@chrischappell9824 2 жыл бұрын

Cutting engines, welding heads, grinding cases and filing metal......it's witchcraft I tells yah, witchcraft!! Thank you Allen, and to see the BBQ getting top billing over Mrs. M, steady on old boy. Looking forward to seeing the next installment.

@rayfraser1773 2 жыл бұрын

Buisquits and creating an engine from parts ! Absolutely bloody genius ! Love what this man is capable of !

@sparty94 2 жыл бұрын

yeah, lets hacksaw a couple of engines apart and weld them together to make a bigger engine- simple. you are a treasure allen, what you do is amazing.

@brianmac8260 2 жыл бұрын

I'm sure that old lawnmower trembles every time you walk by. Great stuff Allan.

@retromechanicalengineer 2 жыл бұрын

You live a charmed existence man! Tea and cookies delivered and Kawasaki two strokes languishing in the shed! When I clean out my garden shed I get a dead mouse and some old creosote. Always enjoy seeing the Elliott mill in action. Great video as usual. Best wishes, Dean in Oxfordshire.

@Bevoin1970 2 жыл бұрын

Speaking as an Ex-Toolmaker (Bench-hand) You inspire me to want to get back into engineering. I look at your equipment in you small workshop, AND what you do! and feel as if Im missing out on something I once did on a daily basis but now kinda miss. Believe me! if I had a small premises fitted out with a Bridgeport, a surface Grinder, bench, vice and surface Plate, I'd be as happy as Larry. I would never have believed I'd be saying that as I once "Clocked in" at 7am on a Grey Monday morning...lol - Must be my 60 years of age mellowing me. :-) - Keep up the Brilliant work!!

@richardkell4888 2 жыл бұрын

I know the feeling, best thing for me was being given Ramapril from the Docs, opens up the blood vessels hence less work for the heart to do and hence I'm much livelier both mentally and physically. A new lease of life, self employed so its much appreciated.

@MrOnly1dad Жыл бұрын

To any normal person this is not possible, To Allen its all perfectly normal, and so easy, Mr Millyard You are one of a kind, an amazing engineer.

@stevenstiles5112 2 жыл бұрын

I think everyone has said what there is to say, thank goodness modern tech allows us all to share and appreciate this amazing mans talent . Thanks Allen and internet.

@strokenumber3 2 жыл бұрын

I'm going to get me one of those Tracys, they seem highly useful....We've all marvelled at his engineering knowledge and design, but this video exhibits Allen's true ability, i.e. skill. Admirable levels of skill.

@RedeyeKnight04 2 жыл бұрын

Thanks for this. You show the essential bits of the operation in this one. I'm looking forward to seeing you sort out the crankshaft.

@eastwood111 2 жыл бұрын

Absolutely brilliant work!

@teterouge1472 2 жыл бұрын

Hacksaw?.... Check. File?..... Check. Good to go..... Amazing skills shown here... Top fella. All the best from North Nottinghamshire

@Wingnut_Stickman 2 жыл бұрын

"Any sufficiently advanced technology is indistinguishable from magic." -- I guess after seeing this video, a hacksaw is sufficiently advanced technology, in the right hands of course. Excellent video, nice looking cookies. Thank you for sharing!

@coinucopia 2 жыл бұрын

If Allen were to ever wind up in prison, they better make good and sure he doesn’t have a hacksaw on him when they put him in!

@diegocella6791 2 жыл бұрын

When we clean our shed we have to hire a truck to remove the junk (and don't lie to your self, is like this!), when Allen clean is shed he pull out to kawaski triple, and decide to join them togheter! He is the man!

@DurokSubaka 2 жыл бұрын

Charley sure moves pretty quick, he was in the shed before you!

@seanys 2 жыл бұрын

You wouldn't really think of a hacksaw as a precision tool but, here we are.

@spitfireace87 2 жыл бұрын

precision operator

@gordonroberts8206 2 жыл бұрын

Love watching a genius at work another great video looking forward to the next one

@robertjohnson7728 2 жыл бұрын

What do you get when you cross a mad scientist, extraordinary engineer, elite skilled worker and a visionary on the level of Nicola Tesla. Allen Millyard.

@stefanmargraf7878 2 жыл бұрын

I am on my knees: you are the godfather of engine rebuilds!

@johnwelburn9966 2 жыл бұрын

Allen is brilliant you really feel like you are in the workshop with him,I have used a hacksaw for over thirty years had expensive ones had dirt cheap ones never had the skill Allen has, great video

@kimmyrask7368 2 жыл бұрын

This video turned out perfect, I’m well pleased with that! Absolutely love this, keep it up mate!

@johndonaldson3619 2 жыл бұрын

I'm so inspired that I'm going to attempt changing the lawn mower spark plug!

@guyholt3757 2 жыл бұрын

"Tracey mixes it all together with a stick" Got to love this man!

@kall399 2 жыл бұрын

Very cool! Your videos actually inspired me to start my own project of turning two Puch vz50n4 moped engines into a "vz100" 2-stroke twin.

@AllenMillyard 2 жыл бұрын

Proper 🙂

@krisholt 2 жыл бұрын

You once promished to show us how you line the drive sprocket up when the engine is shifted sideways in the frame, I hope it is with this build.

@AllenMillyard 2 жыл бұрын

I will cover that in episode 3

@karnashanmugam9789 2 жыл бұрын

I think rear wheel will be reversed sprocket on right brake on left side when engine is alingned sideway

@Cromwell648 2 жыл бұрын

Allen is an engineering genius. If only Isambard Kingdom Brunel, could witness such excellence.

@ikral11 2 жыл бұрын

Brings me back to the past when we were living for the motorcycles. Anyway, me and my darling just took an evening ride on my TDM 900, just to make sure it starts after a month standing still. Works perfect.

@alextripp1230 2 жыл бұрын

Hi Allen, superb video, excellent viewing. Watching you just mark up then cut those cases with a hacksaw.. Englishman in his shed..!!!! So pleased to see you utilised the important tools.. the garden grass and the BBQ.. never fail’s to bring a smile mate. Looking forward to the next instalment. Cheers, Alex.

@ThePianoCentre 2 жыл бұрын

Your videos never fail to impress, I've enjoyed every one . Thanks Allen

@stevennailedit 2 жыл бұрын

Your level of skill is amazing, nothing better than watching a master at work!

@bsport131 2 жыл бұрын

Allen still the only person I know who can cut a straight line with a hacksaw. Once again Im in awe love it .

@dustymiller7758 2 жыл бұрын

Fantastic entertainment. So modest, but an absolute genius. Thanks for sharing.

@brucemitch928 2 жыл бұрын

Really enjoy these videos of Allen’s, the man has serious skills, makes it look effortless. Thanks for sharing 👍

@10trimble 2 жыл бұрын

Very enjoyable Allen, thank you. Looking forward to the next one!

@adrianstrand1120 2 жыл бұрын

More wizardry ! Very therapeutic, doctors should recommend this channel to depressed patients 😀

@willjones7132 2 жыл бұрын

Excellent video, thanks for showing the detail and telling about the burrs and recreating the cast finish, etc.; these videos always help to spend more time on projects, those cookies look great too.

@trevellyanblack4101 2 жыл бұрын

Absolutely fantastic, I was rooted to the spot the entire video. A great privilege to watch a grand master at his work.

@victorpelini5995 2 жыл бұрын

Allen is back at it slicing engines in half wit a hacksaw. Not even surprised anymore tbh 😂 made my day

@JDnBeastlet 5 ай бұрын

Mere words cannot express my admiration for your skills, your appreciation of Tracy's baking, and your care for visiting birds and animals. For all you do, Allen... thank you.

@tomtruesdale6901 2 жыл бұрын

I am always blown away by your knowledge, skills and abilities to do fabrication in "your shed" to such high standards. Will be following this build with great interest. As always Tracey fuels the build with her wonderful cooking.

@sefton1972 2 жыл бұрын

Allen. That was magic. You really do use a hacksaw. Just amazing. That lathe is a must in your world too. There is nothing you can’t make or alter on that machine. Top drawer. Looking forward to the next video.

@odl21 2 жыл бұрын

You mean mill?

@kr46 2 жыл бұрын

I miss my Shed, Thanks Al for for your patience with us mere mortals ..

@brokenbonegarage8910 2 жыл бұрын

More cylinders, hacksaw cookies and the ol barman watching every move. Can't ask for more, wait I do want to see more lol

@MM_in_Havasu 2 жыл бұрын

Quite a fascinating process that you use here, Allen, to manufacture a complete set of crankcases for the 4 cylinder engine! As always, thank you very much for sharing the detailed yet simple process of adding an extra cylinder(s)to an engine! Cheers to you!😎👍🍺

@terrytopliss9506 2 жыл бұрын

RESPECT Allen, your skills are to be admired. I’ve been an engineer most of my working life and never saw anyone better than you.👍👍👍

@rolandwheeler4842 2 жыл бұрын

There is only ONE Allen Millyard. I wish he posted a video every day!

@thedarkknight4243 2 жыл бұрын

someone, please give this man an award, a Nobel prize in Mechanical Engineering and a doctorate

@richardwhittle2302 2 жыл бұрын

I'm amazed at the skill you have to do this particularly your ability to cut through the engine blocks with a hack saw. I couldn't do that to save my life! 👍👍🙂

@w.w.2restorations.vehicles698 2 жыл бұрын

I've been waiting patiently for another video from You Allen, and You didn't disappoint!! I love the Triple Cyl. Two Cycle Engines, but they sound more evenly balanced and more ferocious with 4 cylinders. I can't wait to see more of THIS build. Thanks and good on You mate!!

@KevinSimpson_MTB 2 жыл бұрын

I watch all of your videos with my mouth open, in awe of your skill Allen. You truly are a genius.

@gertrudebeadle5395 2 жыл бұрын

it's not how to cut, but where to cut !! allen certainly knows both !! a master at work !!

@peterdawson7775 2 жыл бұрын

Beautiful work Allen , really good to watch . Really keen for the next installment, cheers.

@robertandersson8171 2 жыл бұрын

Nicely done! As always!

@MegaDirtyberty 2 жыл бұрын

Just a man and his ideas, all powered by Tracey's baking!.

@davepilko66 2 жыл бұрын

The potential for stuff to go wrong at every stage is pretty big but never puts a foot wrong, in a garage, hacksaw etc. Can't get my head round how he does this. Blokes a genius full stop 😅