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

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

[@gasdive]

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

[@barrymartin3813]

And with a 2nd hand blade, amazing

[@dozer1642]

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

[@robertjarmai2627]

This is pure magic.

[@ossanyberg]

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

[@jonasasterlund]

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

[@carleddison7479]

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

[@alexmorgan3435]

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]

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]

Come for the fabrication, stay for the baked goods.

[@GodmanchesterGoblin]

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]

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

[@TibianoUru]

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

[@paulhewson4600]

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

[@juanmcmahon7765]

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

[@leonsutanta6409]

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]

Electic vehicles run on coal

[@gamemeister27]

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

[@BibtheBoulder]

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

[@tomthompson7400]

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]

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

[@ParaBellum2024]

@@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]

all being well the crank video will be up next Sunday

[@stanleydenning]

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

[@kriswright1022]

@@stanleydenning Never seen him use one, ever.

[@bunkie2100]

“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.

[@dukiemoto8676]

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.

[@TurbodanNM]

I will never tire of these videos.

[@olih27]

Amazing level of accuracy performing those cuts with a hacksaw

[@rogermckenzie2711]

Us mortals are still in awe!

[@PillSharks]

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

[@victorpelini5995]

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

[@rogermckenzie2711]

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

[@victorpelini5995]

@@rogermckenzie2711 yeah, these videos are so relaxing

[@Byzmax]

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.

[@kasperkjrsgaard1447]

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

[@stephenthompson6049]

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

[@mastercylinder1939]

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

[@kennywallace1]

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]

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

[@kennywallace1]

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

[@eliotmansfield]

‘and you get there in the end’

[@tam1381]

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.

[@lawrencekeating5571]

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 👍👍

[@harezy]

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

[@AllenMillyard]

hmm I noticed that in the edit 🙈

[@DifferentRides]

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

[@jeffzekas]

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]

Some of the best english engineers were Scottish...

[@Shane-zx4ps]

@@trevormj. Best invention ever was the radar.

[@gavind9487]

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

[@fromgermany271]

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. 😎😎😎

[@paulhall170]

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.

[@doctordapp]

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!

[@47MasoN47]

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]

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]

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

[@davidelliott5843]

Allen is 3D thinker extraordinaire.

[@robertwoodliff2536]

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]

@@robertwoodliff2536 , and West System.

[@twentyrothmans7308]

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]

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

[@barkebaat]

What I learned from this: It's not about the tools, it's about the skill & knowledge.

[@joseywales3789]

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]

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

[@richardhall9687]

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.

[@Jones-xx2gc]

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.

[@Mr-ue2ul]

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

[@michaelarchangel1163]

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.

[@jannemec4567]

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

[@stevenstiles5112]

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.

[@adrianstrand1120]

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

[@Banditmanuk]

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

[@markrigg7038]

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

[@tca375]

Amazing work with just basic tools for the most part.

[@diegocella6791]

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!

[@fergavilan132]

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]

Thankyou

[@retromechanicalengineer]

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.

[@stefanmargraf7878]

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

[@sparty94]

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.

[@seanys]

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

[@spitfireace87]

precision operator

[@animalian01]

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]

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

[@danmanthe9335]

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

[@seankearney6915]

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

[@tomthompson7400]

aac ?

[@animalian01]

@@tomthompson7400🤔

[@nickrider5220]

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 !!

[@thedarkknight4243]

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

[@coinucopia]

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!

[@chrischappell9824]

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.

[@MrOnly1dad]

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.

[@ronhuffman7973]

Thanks Allen! Enjoy watching you demonstrate your skills!

[@rayfraser1773]

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

[@strokenumber3]

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.

[@rolandwheeler4842]

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

[@mikelefevre1701]

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

[@Wingnut_Stickman]

"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!

[@RedeyeKnight04]

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.

[@robertjohnson7728]

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.

[@MrRobinwhatley]

Thank god this man uses his genius for good rather than evil.

[@rockypup1968]

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

[@kimmyrask7368]

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

[@rootboycooks]

Got a couple of 3 cyl engines laying around? let the Mad Genius of motorcycles work his magic hacksaw on them and turn two into one big mother scratcher! Rock On A.M.!

[@Cromwell648]

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

[@Bevoin1970]

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]

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.

[@johnwelburn9966]

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

[@jonnycando]

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!

[@tomgarney7700]

Allen deserves his own Discovery Channel motorcycle show.

[@gordonroberts8206]

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

[@alextripp1230]

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.

[@meirionevans5137]

Of course, none of this is possible without home-made cookies and tea. And a bbq.

[@brianmac8260]

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

[@kall399]

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]

Proper 🙂

[@ThePianoCentre]

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

[@Ralph2]

Quite simply extraordinary.

[@davepilko66]

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 😅

[@brucemitch928]

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

[@terrytopliss9506]

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.👍👍👍

[@ikral11]

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.

[@victorpelini5995]

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

[@robertandersson8171]

Nicely done! As always!

[@sefton1972]

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]

You mean mill?

[@rickr2029]

This is so cool seeing these already incredible bikes (the Kawasaki triples) from my adolescence and seeing what could have been with even more displacement is bizarre. Bizarre in the most envious way. Such a chill dude too!! Love it!!

[@nightster6378]

Greta will be livid when she sees this. An absolute gentleman to show how YOU does this, Matt from The Workshop will be transfixed watching this in learning HOW to do it required when he decides to do the challenge he accepted to build something better than Allan Millyard. I would put this comment to him on his channel but he has me blocked from commenting and my comments have been removed. Allan you must be crapping yourself, you may up your game. lol.

[@dustymiller7758]

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

[@richardwhittle2302]

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! 👍👍🙂

[@MegaDirtyberty]

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

[@kr46]

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

[@MM_in_Havasu]

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!😎👍🍺

[@w.w.2restorations.vehicles698]

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]

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

[@bsport131]

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

[@trevellyanblack4101]

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

[@krisholt]

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]

I will cover that in episode 3

[@karnashanmugam9789]

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

[@JDnBeastlet]

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.

[@eastwood111]

Absolutely brilliant work!

[@tomtruesdale6901]

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.

[@SoddingaboutSi]

Absolutely brilliant. Look how easy it is!

[@guyholt3757]

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

[@steveman1982]

I'll have to watch this again, to make sure I did not just imagine someone fusing two crankcases together. Astonishing.