Kawasaki S1 four cylinder top end build and cylinder rebore - How its made - Episode 6

[@Supercell725]

Watching Allen rebore a cylinder head is more entertaining than anything on tv in the states.

[@GregVirgoe]

I turn on my phone and open the KZbin app. I click on the subscription icon and there’s a new video release by Allan Millyard. So I’m really pleased with that 😃

[@depthsounderdave]

But you didn’t get fresh cupcakes did you? *edit* I posted this before I even got to that part of the video 🤣

[@GT380man]

Indeed, it fits perfect into my day.

[@sungear]

I am well pleased. It's just perfect.

[@kimabella613]

Just perfect

[@jerrywhite7269]

And it's just perfect.

[@yodamaw]

Allen is such a legend that they even named a scew after him.

[@rattusnorvegicus4380]

I thought it was Allen Bolt, because he`s very quick too :)

[@Doug791]

I do believe they are called cap head screws/bolts. An allen key is used to tighten/untighten them. Chairman of the society of pedantics. Sorry.😁

[@bananabrooks3836]

@@Doug791 l think the position is 'Chair' these days, so you've failed in your duty and are voted out.😁

[@Doug791]

@@bananabrooks3836 I would like to sincerely apologise. I would ask that my family be given time to get over this heinous oversight. I'm going out for a walk now , I may be some time... 😂😂😂

[@GT380man]

@@Doug791 Ah, if I knew that, I’d forgotten it. I knew that “cap head screws” were “Allen bolts”. I didn’t know that the Allen attached only to his keys 🤗

[@toodle171]

Tracey is a legend. My wife would NEVER allow me to have such liberties at the kitchen sink.

[@JamesSmith-op7yc]

Oh, I get that one. Thanks for sharing, J.

[@helistorm98]

Oh, and your wife should make a cooking channel, everything she makes seems really good

[@waterboy8999]

I thought this was it, with a bit of hacksaw action added in.

[@oliverjocher2999]

Tha Allen Millyard cooking school of engineering...Best of both worlds really

[@joshuaferguson5756]

Hear hear!

[@MultiMag357]

Your a very lucky man Allen with a wife like Tracey looking after you

[@justing7168]

Allen is the pride of Britain. Your methods are just so sound. I am certain you influence people to think and work better. Thanks for the best videos on here.

[@johnrheiner3234]

God bless you Allen. Your videos are so well done with a beautiful cadence. I get lost in the moment watching them and when they are over, wish there was more. I have learned so much from watching you work, and I will never discount the importance of a hacksaw or barbque pit ever again.

[@doublenickel1000]

You've hit upon the word--"cadence". Yes. That describes his delivery/photography/technical work/observation of wildlife/showcasing Tracy's kitchen skills/etc. perfectly. Bravo.

[@marvinkumarparboteeah7822]

the accuracy of the cylinder boring machine, the amount of batter in the cupcake...just perfect. i remember my metalwork classes when the teacher would shout about "precautions to be taken when tapping a blind hole". thank you for the perfect videos

[@slartybartfarst9737]

Allen got me again, I've always wanted to know how those reboring machines got the bore aligned especially as I've painstakingly rebored on a lathe in the past which included turning a flange on a faceplate to avoid chucking the barrels. That's me screwed I want a reboring machine now. Brilliant camera work showing the exact view that describes the process........ with cake and robins for good measure!

[@utubedaveg]

I just bought a Bridgeport milling machine. I assume with the right setup i can bore a cylinder. I am overhauling an s4 kawasaki.

[@slartybartfarst9737]

@@utubedaveg with something as substantial as a Bridgeport you can bore a cylinder with a substantial boring head (adjustable radious cutting) and clock it to centre dead ctr or you can make your own ideally you need some mass in the tool to minimise vibrations off the ports if it's 2 stroke barrels, 4 stroke is easy almost any boring tool will do the job

[@the_forbinproject2777]

@@utubedaveg ping Allen , see if can help ;-) ( only kidding Allen )

[@simonbirt6121]

Me too, brilliant machine, much easier than a lathe or boring head on a milling machine. I imagine finding one will be difficult.

[@grenvillephillips6998]

Rebores were very routine back in the old days, and I always wondered how they did it - its great to find out!

[@grenvillephillips6998]

@@gpw203 I can remember a mate of mine, doing a rebore on a lathe, but sadly the lathe had been left with the taper-turning attachment engaged. Doh!

[@rattusnorvegicus4380]

@@grenvillephillips6998 Hope he found a concertina-tapering piston to match.

[@martinda7446]

@@gpw203 😹😹😹

[@ChasingTenths]

Such lovely simplicity in the narration & production, no faffery .

[@GT380man]

Allen’s technique with the circlip pliers is so well controlled that I noticed he didn’t even block up the open bottom end. I always do, because I often drop the darned circlip!

[@rogerbarrett9920]

Haha - Even though I've built many engines I still cover up the crankcase, the thought of dropping the circlip makes my hands shake!!

[@epj900]

Hello Dr Yeadon!

[@_pld]

I like how none of the circlips are lined up the same way, one horizontal, another vertical, no rhyme or reason, just do whatever you feel like!

[@r1273m]

That was fascinating, I have never seen a rebore done before. I thought that getting the barrel central would be more complex than that 3 pin system.

[@MaciusSzwed]

You´ve never watched Pakistan mechanics? Check em out, they are not as precise and inventive as Allen though...

[@GT380man]

I too didn’t know how that step was accomplished. Very interesting! I knew honing with a stone & of course top end rebuild.

[@Afro408]

KIS principle. 😉👍

[@markhensley9378]

I've never seen an engine boring done. Didn't know what to expect from this process. Thanks for giving us so much detail about it.

[@joseywales3789]

@r1273m, often the simplest solution is the most elegant. A tri-lobe cam pushing against the diffrent sized rods for the diffrent sized bore and....... Robert's your Mother's Brother! *It's CENTERED!"*

[@Nickdifilip]

Allen when you go into detail about her baking I sometimes forget I’m watching a motorcycle video. Who knew baking can be so captivating…

[@keithgarland3404]

Bloody brilliant. Love all your tools and equipment as well as your skills. Your work is absolute quality.

[@schzx14]

Your attention to detail, such as machining the head of the head bolts, is inspiring. The fact that you make your own head bolts is beyond amazing. The cupcakes look great too.

[@charlessmyth]

Very compact for a 550. Between the Dremel wandering across a bore and dropping a circlip into the crankcase, there's no end of tiger traps to befall the assembler :-)

[@GT380man]

Hands up who’s done both of those. Hmm. I have! Tell you what, though. You don’t do it twice.

[@chrishartley1210]

I was wondering why there was no rag to stop the circlip falling into the crankcase, I wouldn't have dared fit them without.

[@williamcollins4082]

Was surprised an the no rag confidence or even cow magnets . Took 1/2 a day with my clumsy mitts once. It can become an interesting fishing operation !!! Ole man Murphy's Law . If it can't possibly happen it will !!! Some magnetic tools are a great confidence builder.Especually with tiny parts.

[@shelleyking8450]

So calm and organized, with a beautiful result. Allen is the British Bob Ross of "men in a shed" mechanics. It makes me feel like I could do wnat he does, even if I know better.

[@Shining_Whit]

Its channels like Allen's that makes me realize that getting rid of my TV and the associated license was no loss at all! Brilliant enthralling content with baking and some nature thrown in for good measure. Happy new year to all!

[@erik_dk842]

Who needs TV in this day and age? It's either lowest common denominator entertainment or blatant lies and propaganda.

[@flyonbyya]

Love watching the use of all the top quality old English tools and equipment in the shop!

[@jimramsden2911]

Allen thanks to you the mystery of cylinder boring is de-mistified . Thank you. I appreciate your videos sooo much. You explain things so simply and beautifully. Your filming and editing is just as simple and elegant as your bike building. That in itself is a craft. I love the contrast of your machine work with the appreciation of your wife’s baking and intercuts of squirrels, birds or what ever. Your ‘Boyish’ enthusiasm is infectious. I use music to relax and now I use your videos to do the same only in a mechanical way. Any project you accomplish always makes anything I do seem like a Piece of Cake. Please keep up the Amazing Work! Genuinely, Jim

[@sefton1972]

Thank you Allen for the time & effort in making these videos. Truly amazing viewing. Looking forward to the next instalment.

[@grahamsengineering.2532]

Hey Allen, I forgot to add. I love the old Cylinder Boring Machine, and you got all the original tooling with it. We have simular in Australia that would sit on top of the engine block like yours and were made by REPCO, could do a 6 cylinder car ehgine with one. I've never seen the stand that you have for doing Bike Barrels. Very nice.

[@jostouw4366]

They work just fine on multi cylinder blocks as well just screw a large headed bolt into a head stud thread. spent many hours watching them make swarf our shop had a couple of them on top of the motor there is a diamond lap to sharpen the cutters.

[@jimmymac9388]

A Millyard vlog wouldn't be the same without Charlie and one of Tracy's cup cakes.😄

[@ianedwards26]

a true engineer ,,so much time taken

[@paulhall170]

I swear the original engine didn't look that good when it came from the factory! Allen, you are a perfectionist, and we love that!

[@crafter170]

What a team.I would love to have neighbours like this.

[@dwightbrown2808]

I love the parts with the birds and cupcakes :-) Allen has such a nice voice, I love these videos. I watch them several times.

[@dannycoultas265]

I could watch you work for hours the level of fine detail is unworldly leaves me in ore each time i watch absolute genius

[@GT380man]

Awe. We’re all filled with awe when watching Mr Millyard! Ore is stuff in rocks, like iron ore.

[@dannycoultas265]

Who cares u understood

[@deandee8082]

everything you touch turns to pure gold Allen, your bikes will live on forever, I can't see a one of them ever being scrapped and the way you build marking and documenting everything they will be rebuilt time after time.. 5000 years from now your bikes will be ridden and admired by all to see...

[@philtucker1224]

Allen you’re absolutely right about those sleeve bolts, they look absolutely pristine on the top of those cylinder heads! (Can’t wait to see the episode where you make the exhaust headers) - this engine is gorgeous. Nice work 👍😊

[@bugproductions9050]

As far as I'm concerned, it doesn't get any better than this channel. It's "just perfect". Im guessing Tracey loves it when you run a bubble bath for your barrels in the sink.

[@boostaholic7116]

Can't wait to see the next installment and hear this beast fire up! It's a work of art, Allen you are just so skilled it' makes me proud to be English 👍🏴󠁧󠁢󠁥󠁮󠁧󠁿

[@crabapple1974]

These are so nice and interesting to watch. The mild mannered tone as a contrast to the crazy precisionwork beeing done with almost ordinary tools! He lets his skill speak for itself. Very relaxing to watch and you want to sit in that kitchen eating those muffins. This is such a stark contrast to any of the shouty “standing with my legs too far apart with arms crossed” american shows.

[@walkingpictures]

Another fascinating video Allen and a full set...Charley Weaver smiling after all the rum...Tracey's cup cakes....and some great engineering...Just Perfect. Thankyou again for this latest update and very best wishes to you all for 2022..Kimbo 😊

[@GT380man]

Not forgetting the Robin!

[@utubedaveg]

never get tired of watching you work Allen.

[@WiltshireMan]

That was amazing Allen, the top end was a top job and the cup cakes were topped off rather well too :) Happy New Year

[@ThisRandomUsername]

Nicely done making the comment that was plagiarised by the bot.

[@billmoran3219]

What motorcycle mechanic out there hasn’t used their kitchen as a shop! Great video Allen much respect for your detailed work 👍🤙✌️

[@danielruscanu5772]

Sir, you are a true legend, you really inspire me to start learning more about engines and stuff like that and try to repair and even try to modify engines like you do!

[@russfoggan4092]

Always for me one of the most satisfying things about putting a 2 stroke back together is pinching the rings and dropping the barrel back on!

[@mrsmith4662]

I love all this imperial units, hands-on analogue micrometer, careful measuring (twice) and cutting. Proper craftsmanship. 'This part of the process is critical'. You're telling me. - whether it's the cup cakes or the re-bore (never seen that done - facinating) or making the stainless sleeve nuts. Love it all. The build is really taking shape. Roll on the next stage.

[@openidqd]

Micro meter - not imperial. Micro inch may be better? Lol

[@75L48]

Thank god this is the only episode he actually used imperial.. and thats because he had to. Metric ftw.

[@533MrHappy]

I cannot get enough of this. I have a 2018 Honda CB650F and a 2007 Suzuki GSXR1000. I work in motorcycle insurance, at a company that is popular with classic bike owners. I've been interested in getting my hands dirty, but approaching my bikes with a spanner as a 31 year old newcomer is daunting. Taking an allen key to my bike the first time resulted in a broken bolt, so I've been reluctant since. I have a handy friend who has helped me with a few things and is currently rebuilding his 955i Daytona after an accident. Your channel has truly inspired me to keep getting them spanners out, thank you

[@aronANDtanner]

Love watching you work, it's masterful! I had to buy my bike with an inline 6 to start, it's wild to see you do this in your shed.

[@GT380man]

CBX1000?

[@WhosAGoodDogue]

Z1300 Kwacker?

[@Banditmanuk]

Absolutely fascinating. Just proves some of the old machines and measuring equipment still work perfectly in skilled hands. Looking forward to hearing it start.

[@dirtytruckhotrodshop7829]

Always a fan of your work! Makes me miss my days in the machine shop!

[@tonyw3250]

No way I'd ever not use a rag to stop me dropping a circlip down the crank - Allen's confidence is second to none👍

[@HariMahadevanKoovappady]

Thank you Allen. I was waiting to see how you would align the boring machine to the dead center of the cylinder. What an ingenious machine! Simple, but effective and no need for fancy CNC setup!

[@MrEtnorb]

I love cooking and motorbikes. This is the perfect YT video, combining the perfection of Allen in the shed and Tracey in the kitchen. An impossibly high standard has been set but I expect it to be bettered in future episodes.

[@wildracoon666]

Another great job allen you make everything look so easy, can't wait to hear it run😉

[@iancharlton678]

Back here again on a Sunday…..🎉 Starting with lawnmowers, then my FS1E, GP125…… KH250 etc etc……. forever taking them apart in the vain notion that by polishing, we could make them quicker 🥳 A mate had a boring bar of similar vintage, never sharing its black arts……. Now I know !! Wonderfully explained and filmed as always Allen…….. your knowledge and expertise are only equalled by your skill with a camera……… and that’s just the baking 😂 As always, thank you……… and do please continue. 🇬🇧🙂

[@martinholt2844]

Yet another masterclass made to look simple and everyday Allen! 👍

[@johnmccarthy5132]

Genius, hedgehog minder, bird watcher, cupcake muncher and one of the most interesting KZbin contributors i can find. I never miss one of his videos! Bought of of his flying Millyard t-shirts. It's a prized possession!

[@AllenMillyard]

Thank you

[@Arni0111]

I love your videos, it is truly amazing to see you work and look forward to see this engine run.

[@kimjessen737]

I always get sucked into these videoes. Born 1963 these bikes are the bike the older boys drove when I was a kid 😊

[@drn6073]

Brilliant Allan thank you for showing the process of your build I really appreciate it I'm looking forward to the next stage 👏👏👀👍

[@myadventuretime4269]

The kitchen sink? Your wife must be a very special lady! Love your work on the bikes and the videos. Nice to see the recipe becoming a regular installation.

[@ИванИванов-щ9ч1т]

Супер, все так доступно и понятно. Просто нет слов! С нетерпением жду следующую серию! Удачи👍

[@brandywell44]

Translates as "Super, everything is so accessible and understandable. There are no words! I'm looking forward to the next episode! Good luck"

[@martinda7446]

Wonderful stuff. Brilliantly filmed too. We are all so lucky Allen decided to share his engineering genius with us. Fancy a cupcake now..

[@bradcrossman5068]

Happy New Year to you and yours Allen! Thanks for all the vids and looking forward to more. Charley hasn't aged a bit, lucky devil.😉

[@AudreyH48]

Hard to beat classic machinery. It's a simple concept that makes repeatable precision bores, brilliant.

[@mikelefevre1701]

Brilliant- really enjoying this engine build. Happy new year to you Allen & family- you are proper old school!

[@dougedmond3029]

Allan has reached the highest spiritual place in human existence. What a pleasure it is to watch and be entertained by the love of his craft and appreciation for everything that is happening around him.

[@waynebuzzell2483]

Allen, thanks again for sharing your knowledge on the internal combustion engine. Of course thanks to your wife for her knowledge on baking. Love that classic boring machine. Saves a lot of money on shop expenses. Happy New Year and Cheers

[@chequeredflagracing]

Love the old boring machine, just like me, created in 1958 and still working great

[@gazzafloss]

Another fine instructional, "How To" video Allen, it would be absolutely perfect for a mechanical trade class at a Technical school. Great work.

[@richardwhittle2302]

Hi Allen this channel just keeps getting better - I learn everytime I watch including Tracy's Cup Cakes - just amazing and thanks 👍

[@offroad3607]

Nice one Allen, that engine is a work of art. 😍

[@andrewevans7184]

Truly a niche channel, shed based custom motorcycle building and baking all in one place, bloody marvellous .

[@jamieweirdworld]

Thanks for another interesting video! I've soaked pistons in need of cleaning in Dawn dishwashing detergent and water overnight. The carbon usually wipes right off, and is super easy to clean from the ring grooves.

[@stekwack]

Yet another video that doesn't dissapoint, what a craftsman and so is Mrs Milliard those cup cakes looked amazing.

[@jamiemorris3995]

Another amazing video Allen im glad to see the project continuing to take shape and cannot wait for the next part hope youve all had a safe and happy new year and will continue to have a safe and happy 2022 👍

[@grosbeakmc]

Beautifully done and a real pleasure to watch. Thanks for bringing us to your lovely corner of the world again!

[@grapes008]

This and a whiskey the night before my first day back to work, what have I done to deserve this

[@slasher102]

I think you are amazing if someone said can you build a rocket and fly to the moon, you would say "No problem just need my hacksaw and a few hand tools". absolutely awesome Alan. i have watched all your videos, and you never cease to amaze me.

[@helistorm98]

If you need a slogan for the channel: I'm really pleased with that! You use it all the time, it's natural now 🤣🤣

[@lwoodt1]

Mrs. Millyard should have her own cooking channel.

[@frogandspanner]

In episode 17 Allen shows how, with a can opener and Irish screwdriver, he builds a world-beating engine for the 2022 Aston Martin F1 team.

[@mrwolsy3696]

I dont doubt it for second.

[@jerrywhite7269]

That's a good one. LOL

[@thecideralquaeda]

I was loving it up to the dentist bit- I'm having unsuccessful root canal work at the moment... thanks Alan!

[@erik_dk842]

I can feel your pain in the wallet

[@untonyto]

Me simple man: me see Allen Millyard video, me click Allen Millyard video.

[@alanjones4358]

This has to be the best engine building/baking channel on youtube.

[@SoddingaboutSi]

That boring machine is amazing. Hope that Allen grub screws tight! No lube for honing?

[@strokenumber3]

All present and correct; hacksaw, lathe, cupcakes etc. Always mesmerized by Allen's videos.

[@DukeDyson]

Wonderful production as ever Allen. Did you use any cutting lube during the honing?

[@AllenMillyard]

Yes it missed the edit

[@petejay75]

@@AllenMillyard I knew that it had to be something like this, thanks for the clarification.

[@catbreath007]

Ah, So that's a rebore machine ? Clever bit of equipment that & you explained how it works so perfectly 👍🔧

[@ricardolici]

Da gosto ver um trabalho bem feito,obrigado por compartilhar

[@jimclements3190]

People will look back at these videos in 25 years and be just as amazed as I am now, brilliant as always Allen. Have a fantastic 2022 by the way, 👍🏁

[@peterlavin9373]

Really enjoyed this episode Allen. Did you find any variation in each of the pistons and did you need to gap the rings in each bore?

[@GT380man]

I too wondered that, the dimensions. I will say the OEM Suzuki two stroke pistons for their triples like the 380 come up incredibly similar. Not totally identical. What I’ve noticed can vary quite a lot is their masses. I think they must have changed the alloy between the 1970s & now. So it’s well worth checking, especially as in this case, Allen had one piston in stock & bought three more. If the stock piston was decades old & the set of three were recently manufactured, its possible they have different masses.

[@Bobby-fj8mk]

@@GT380man - I noticed that he didn't weigh them to check. If that one piston was a different weight it would cause vibration. He also should have put a rag in the top of the crankcase in case a circlip fell in. That saved my bacon many times.

[@davewestfall1325]

Allen, there is nothing boring about this. Loved it!!!!

[@jeffreylim5210]

The entire engine is perfectly assemble. Can't wait to see the engine start & the sound. Brilliant!

[@davidabbotts3733]

You have a pride in what you do,and are a perfectionist,i like the old school tools you use,once again Allen,you really are a genius .

[@bobstevens9040]

Great to see Allen using Sheffield made measuring instruments. Moore & Wright micrometers were made in Sheffield from 1906 but the factory has moved to Bradford now after a takeover. The boring machine toolkit was made by GKN in their Laycock engineering plant also in Sheffield , now no longer with us , although GKN still has a presence in Britain. Old school tools for an old school engineer...people , this man is a genius

[@tzajaczajac]

That boring machine is absolutely fantastic what a cool tool to have and still perfect after all these years

[@MartsGarage]

Hello Allen. Thanks for showing the details of the boring machine, the tooling and setup. I fixed up a vintage Buma boring machine, and have made my own tooling. I have successfully bored a couple of Ford Flathead V8s including liners. I was pleased to see how similar your machine is, and the way the tooling is setup is very similar too. I've enjoyed watching this series and eagerly await the next episode. All the best, Mart in Solihull.

[@nealepitts3321]

Does anyone else get excited watching these videos or just me. Just love the way everything fits perfect .

[@tomtruesdale6901]

What a beautiful engine. That bore machine is a piece of art, have never seen one like it before. Those cupcakes look like they are Heaven sent. Yummy.

[@paulnelsonisnotabot]

If you ever stop making cool stuff please do a baking channel with the other half. It's super wholesome

[@globalfallout7249]

Beautiful piece of Engineering Alan. One step closer to fitting it into the frame

[@brodiejones2028]

You're a brave man Allen. No rag over the crankcase while inserting the piston circlips. Obviously never dropped one into the crankcase! Always wondered how barrels were rebored. Thanks so much for sharing.

[@doug1570]

Learn about advanced mechanics and engineering and how to bake luxorias cup cakes in one video. Sheer brilliance! Thanks Mr and Mrs Millyard. Outstanding in your respective fields.

[@mross302]

Allen, you have inspired me to finally build my 4 cylinder 2 stroke snowmobile engine that I have always wanted. A triple to quad conversion.