Millyard Kawasaki S1 Four Cylinder Crankshaft - How its Made - Episode 2

In this video I show you how I made a four cylinder pressed up crankshaft with a 90 degree 1 - 4 - 2 - 3 firing interval. This crankshaft is for my 550cc four cylinder engine that is based on the Kawasaki S1 250 triple engine. Tracey bakes some Christmas cup cakes and our friendly squirrel pays a visit at the end. My old automaton "Charlie Weaver" keeps an obligatory eye on me in between tipples. Hope you enjoy the video
regards
Allen

[@julianlyons711]

What a guy .. talent and old school engineering in a shed.. these vids are like therapy

[@strokenumber3]

In Allen's space, even cupcakes appear to go through an engineering process. You just know each and every individual cupcake is 'within spec'. Thanks AM - and T - for yet another marvellous video.

[@orionwarren4244]

It never ceases to amaze me how you re-engineer and then build engines/motorcycles using comparatively simple equipment with such precision, Allen!

[@savage22bolt32]

And those cupcakes have me in a fit of hunger now!

[@garystratton4125]

I was thinking the same.. How in the world? I would be using the precise measuring instruments as I was going along and Allen just uses them to double check his work... Let me correct that statement...I would not be able to do this...and I (B.I.D.A.) Before I Discovered Allen-- considered myself a decent, above average bike builder...HA! I love this guy.. we can all identify using simple tools.. But to use them at such a level of precision is just ...mind-boggaling:)

[@Reman1975]

@@garystratton4125 Yeah. Usually, if you want to up the capacity or cylinder count on a vehicle, you start and end the plan by looking at suitable engines to swap in. The average person doesn't instantly start by wondering where to graft a couple more cylinders onto the current engine. :D

[@allenglishknives6823]

Watching this fills me with a deep sense of joy and wellbeing. The way she handles that food processor is amazing! 😊👍🏻

[@leifvejby8023]

Just perfect! ;-)

[@a-skepticalman6984]

anyone want to bet that Alan measured the thickness of he marzipan at exactly three millimetres, or was he just making it up?

[@vk2aafhamradio]

​@@a-skepticalman6984 Allen has a well-calibrated eyecrometer.

[@leifvejby8023]

@@a-skepticalman6984 Don't know about Alan, but I use calipers when rolling out marzipan, no need to use micrometer.

[@Reman1975]

Allen does seem to get a certain extra thrill in his voice when he enters the kitchen. :D

[@robsawalker]

There is literally nothing on terrestrial TV I would rather watch than Allens videos. Their whole structure and content, for me, is spot on; it's like 70s programming where things were allowed to be a bit quirky and were just better for it. Never stop Allen!

[@chipper442]

I love that you include Tracy and her “shop” work. You are an inspiration Alan, it’s amazing what you can do in your little shop. Thank you.

[@LesSharp]

Deep down, Allen's a cupcake guy with a motorcycle problem.

[@sungear]

I love the play-by-play. I was waiting for a "I'm well pleased" or "it's just perfect"

[@johnwelburn9966]

Allen explains everything so thoroughly feels like you are in the workshop with him one thing he has never explained is how he keeps so trim with all those cup cakes around the place,great video

[@AllenMillyard]

150lbs

[@chrisford9045]

He keeps trim from all the hacksawing

[@joseywales3789]

Exceptional Engineering, Tracey's Christmas Cupcakes, a love for marzipan, Charlie Weaver and an Easter Egg of the Swiss Army Knife on your workbench! But no need for the Barbecue for the assembly of the crankshaft. Truly an Engineering Genius. Thank you, Allen. 👍🔧🔩

[@tomtruesdale6901]

Your work in your home garage and shed put many "professional" engine builders to shame. You are building what the factors should have built. Looking forward to your next video. Those cupcakes look great !

[@Reman1975]

Most "Professional" engine builders would just tell you that it wasn't possible as soon as you outlined the plans for this kind of project. :(

[@0utcastAussie]

Marzipan MmmmmmmmmMMMmm !!

[@philw4053]

Just that clip that was "easy to remove with a couple of screwdrivers" would have probably kept me busy for a couple of hours. Wish I could be there and watch over your shoulder - and learn from you mate. You are a genius.

[@2STROKESTUFFING]

"It's a nice tight fit, and it grips really well. That's how it should be. Not all loose and floppy like the old ones" 😂🍻 Loved the video, a pleasure to watch!

[@pravgeusau]

You make it look so simple. Great mechanic!

[@FJ80Coop]

Are you talking about my ex ??hunh hunh ??loose and sloppy ? Just how do you know her ? 😁

[@peem1244]

Super video as usual, Allen. Anyone who conjures a 4-cyl K engine from two old 3-cyls will always want more cherries in their cup cakes! Always. Thanks for sharing. Stay safe and keep up the good work.

[@josephreisinger33]

Yes yes, more cherries. And are they 1.5 or 2 mm???

[@paulwheeldon3487]

I wish my 'careers advice' covered mechanical engineering at school, some 37 years ago. Good on you Allen, I'm sure you're an ispiration to todays youngsters.

[@dennis38y]

Absolutely brilliant once again Allen ! Clear and precise demonstrations and explanations, youngsters today could learn an awful lot from your videos. There’s no substitute for experience and your techniques are brilliant. I know the filming and editing takes a lot of time so thank you for sharing as always.

[@bugproductions9050]

The precision, knowledge and skills are second to none. Tracy is an amazing cook. Allen's not too bad aswell!!! 👌🇦🇺👍🇦🇺

[@judynpeterjones3307]

A Master at work, I could watch you all day, no urgency, no expletives and no blood!!!

[@andrewachholz7922]

Im utterly impressed. Not only for your amazing skills but for your friendly approach. A tue pleasure to watch.

[@panosgamithis8868]

It dosnt matter how old I get... Watching Mr. Millyard assemble anything makes me a little more competent in my "MOTORCYCLE WORLD"....!!! THANK YOU MR. MILLYARD.....

[@drott150]

The peaceful little workshop in England where all is well in the world. We need this right now.

[@BerlinghoffRasmussen]

I've never seen such precision cupcake making. Truly a masterpiece!

[@soupdragon5555]

Alan, you do such a good job explaining what you are doing i had to catch myself from heading out to my shed to saw my lawnmower in two.

[@Tod_Unctious]

Hi Graham That would probably be my 1st project the lawnmower. But I would end up with a pair of shears or something even worse that didn't work very well.

[@chrischappell9824]

After watching your videos now for a long time I still can't believe how you make this look so easy and us mere mortals know it isn't. Cracking work Allen, roll on the next one.

[@jeffbridges666]

Allen, you are a genius, what an amazing creation by a man in his garden shed 👏

[@wdhewson]

As well as admiring Allen, we must praise the Japanese m/c manufactures for their precision work at affordable prices. Tell Tracey, I could smell those baking cupcakes all the way to Sarnia, Ontario!!

[@michealtaylor2542]

I wonder if Tracy is secretly making a 4 cylinder mixer?

[@classicraceruk1337]

A great watch Allen, who would have thought watching parts pushed on could be so absorbing. Of course it does bring back memories of building our own race engines back in the 60’s 70’s and 80’s. This sometimes was weekly after blowing them up at the weekend!!!!

[@rodintoulouse3054]

Thank you allen. Seeing you work and listening to your stories is like therapy. So relaxing. It doesn’t matter that I don’t understand most of it. 😁. You give out all this time and knowledge for free and from what I see your fantastic production is very limited. How do make a living? Is it selling Tracey’s cupcakes?

[@DBMac58]

It’s just amazing how you have mastered Kawasaki Triple Engines. New parts for old parts, you have great connections in the land of Kawasaki Two Strokes.

[@G58]

If only Honda crankshafts were made the same way, my latest crazy idea would be a lot easier. Thank you for sharing Allen. Inspiring as always.

[@AmateurRedneckWorkshop]

I enjoyed the video. I used to rebuild a lot of crankshafts and I showed how to do this in a video and I caught a lot of flack from some folks who were certain I did it wrong. It appears your viewers are better informed. Thanks for the video.

[@GregVirgoe]

Here’s me expecting to see turning and welding and grinding. No you just push on another one. That’s very clever fore thought in the initial design stages. Nice 👍🏼

[@Tod_Unctious]

Hi Greg, I was expecting welding etc, I didn't realise that extending crankshafts was like playing with Lego. I reckon this engine building malarky is easy. 🤭

[@daos3300]

the beauty of modular cranks.

[@dord1954]

I thought the same thing, I’ve only ever stripped car engines which are obviously completely different

[@jimclements3190]

@@Tod_Unctious in your dreams 😅😅

[@Reman1975]

@@Tod_Unctious Assembling an engine IS easy. The skill comes into play when you have to bolt it all together in that one configuration where it will still work. :D

[@karlosvulture5014]

I've said this before and I will say it again, I wish I just had a third of this man's skills......just a third and I would be so happy.... good on you mate love your work..!

[@zebdeming]

That bearing puller is absolutely brilliant! I have never seen one like that

[@AGEngineering]

Gedore 1.29

[@nathanielpea5819]

This level of skill and imagination is pretty special. I wish I had 10% of the talent of Mr Mill yard, but people have been doing the same thing with car engines in the US for at least half a century. Its nothing particularly new, just very very skillful and shows unusual ingenuity.

[@CS_247]

Excellence in all departments, as always, in the Milyard house! Awesome how simple you make that process look, I changed the bearings and seals on my GT250, and it was a mission!!

[@alexwilsonpottery3733]

Love seeing your videos. I once heated up a crankcase in the oven to get a bearing out - no blowtorch, press or pullers available. For some reason my flatmates didn’t like the smell of crankcase oil…some people, I ask you.

[@dronebandit1292]

You make it look so easy Lovely to watch the assembly of the crankshaft can’t wait to see the rest of the Engine coming together top class work

[@minnesotatomcat]

Recently started watching your videos and now I’m thoroughly addicted. As a fellow gearhead I’d love to sit and have coffee with Allen and just pick his brain for an afternoon. He is a genius among geniuses and I can’t get enough of watching him.

[@mrsmith4662]

As always, amazing. Love the crankshaft assembly, love the cupcakes (made with the same precision - to within a thou). All delicious.

[@TROdesigns]

I love these videos - we're lucky to have an archive of this moto genius at work!

[@jdmjesus6103]

I think what Allen didn't fully describe is that the initial position of the first rod pin in the lathe doesn't matter, as long a it's somewhere near either the top or the bottom. Being straight up or down gives the most rotational accuracy when it's locked onto the tool post. Then it's just a case of rotating it exactly 180 deg. Very clever. It had me guessing at first as I couldn't see a dial indicator on the first pin, I didn't know how he got it at top dead centre, then I realised it doesn't even need to be. Excellent video!

[@silentunicorn6526]

This took me a moment to understand as well. As long as the tool-post isn't moved after the first position is set, all is good.

[@obsoletearchive4201]

Poetry in motion, Really enjoyed watching the process of repurposing parts from two engines to create a modified crank. thank you for posting.

[@David_Owsnett]

I love seeing how cup cakes are made!

[@loydsa]

Perfection as always Allen! A really clear video illustrating the process you follow, and of course, more importantly the process Tracy follows for her Xmas cupcakes :-) Best regards to you both Sarah

[@garythompson883]

Hi there, when I first watched your video I was expecting a workshop full of specialized machines. To do this kind of work in a backyard shed renders me speechless. Truly amazing.

[@yoochoobb]

15:55 Verified with dial calipers, no doubt :) Enjoyable as always, I love these videos.

[@kimabella613]

Exactly 3mm

[@bsport131]

Another thoroughly enjoyable videos to watch while drinking my morning tea, so much more relaxing than watching the news. Thanks Allen

[@oldschoolmotorsickle]

I find the crankshaft throw arrangement fascinating. The usual cross plane staging puts the 180 degree split between cylinders 2 + 3; this creates the effect of a 90 degree twin paired with another 90 degree twin, out of phase by 180 degrees. Mr Millyard places the 180 degree splits between the cylinder pairs, creating two 180 degree twins separated by 90 degrees. I imagine that either design creates a beehive of buzzing at the grips at high engine speeds, but which one is better all-round?

[@a-skepticalman6984]

we await the results with much anticipation

[@LesSharp]

Yes, it's very interesting. In his previous fours, he's used a two-plane arrangement, with crank pins at 90*. The way Yamaha used to do this, with the TZ500/700/750, had it fire like two twins strapped together. Single-plane, outer pistons in parallel, inner pistons in parallel, 180* apart. This one seems to have cyls 1&2 at 90* to 3&4. This might create a bit of a rocking couple. Looking forward to the results.

[@oldschoolmotorsickle]

No need to wait for results, this is the same layout of his other four cylinder bikes. The old TZs fired two cylinders simultaneously, then after 180 degrees of rotation fired the other pair. Allen’s design brings one cylinder to TDC every 90 degrees, but not in the style of the Yamaha R1 cross plane design. My curiosity revolves around the the resulting secondary imbalances, and how that affects the overall feel of the engine and what type of vibration “signature” it would create. We’ll have to ask him to create another four-cylinder with the alternate firing order and submit it for testing!

[@marvinkumarparboteeah7822]

The thinking process followed by realisation and not to forget the energy supplier....amazing...God bless you all...Merry Christmas

[@stephenwilliams926]

This plus this old tony in the same day 🙂

[@Sun-ut9gr]

I've always liked the sound of a cross-plane 4. Awesome, Allen!

[@bikesmith]

Unfortunately, the like button can only be pressed once!

[@urankjj]

Crankshafts, cupcakes, and copper hammers. You make them all fit together so well..... Thank you.

[@ChumbahNutz]

It's a well known engineering principle, that marzipan is never ever exactly 3mm.

[@kmc7355]

Especially once i've used it as plastiguage.

[@jeffdavies688]

I am quite confident that in the Millyard kitchen.....Marzipan will be exactly 3mm....

[@tomtruesdale6901]

Except when Tracey makes it.

[@deancoley7987]

When watching the master at work, I feel like I've been hypnotized, sheer magic

[@paulnelsonisnotabot]

The videos keep getting more wholesome, we must protect this man and wife at all costs

[@derf9465]

Best collection films on youtube. Well put together, smooth calm and great narration. Much like Chris yates, a fisherman. Id say Allen is an idol, great character. Thankyou again. Cant wait for the next video.

[@StonyRC]

Allen, you are such a GEEK ... I mean that as a mark of my deepest respect and admiration. Excellent video.

[@davidreed6817]

Utter genius!! Notice how the marzipan (yuk!!) was exactly 3mm thick and all the trees pointed the same way! that's an engineer for you

[@bjoernandersen8287]

Another great video from the workshop with a nice cup of tea and homemade cupcakes. Thanks for sharing.

[@Usfwood]

I love watching your videos. I get lots of ideas from them. How you do some of your builds truly takes some out of the box thinking. But my wife was watching and demanded I comment and ask for the cupcake recipe. Go figure...

[@gabrielmarocco9667]

Sr, Allen. Usted es un ingeniero impecable, su dedicación y amor por las motos y sus motores. Es algo que me deja siempre, sorprendido. Me gustaría que sus videos tengan subtítulos en español. Ya que la única opción es en inglés. Y cada uno de trabajos reflejado en estos vídeos en KZbin son más que un lujo! Desde ya muchas gracias. Y espero que se pueda realizar en más de un idioma!

[@Shining_Whit]

So satisfying to watch! I find your videos fascinating and somewhat calming. Tracy's baking is just the icing on the cake so to speak! 🧁

[@andywawa7227]

Allen, you've got such amazing skills so elegantly and effortlessly presented, as if it were the simplest thing (which is not!) in the world. Simply great done!

[@TheMegaross91]

I don't know what I enjoy more, that technique using the lathe to assemble the crankshaft or these brief breaks for Tracey's assembly of delicious engineer fuel

[@zumwild]

Really appreciate the attention to sharing just enough detail. Pretty confident I could make my very own cup cakes now.

[@jdudb]

I am always blown away by your simple but effective engineering, a rare skill. I would love to see a video on your Velocette engine which I think is my favourite of all your conversions. More please!

[@jumpfortyfour9965]

thank you Allen not just the work on the crank but super filming of it all . not forgetting the cake making .

[@johnmccarthy5132]

Look, I can't explain why this is so enjoyable. Maybe because Allen does impossible stuff and makes it look easy. Charley Weaver and I approve!

[@GT380man]

I wonder what young Allen & Tracy were doing 40 years ago? Engine building & cupcakes? They’re like a timeless couple living in a bubble of perfect southern Englishness that hardly exists any more. Warms my heart.

[@minnesotatomcat]

I just love to watch his thought process in building things and how he doesn’t always have the ideal tools or machines but uses the tools he does have to do such a precise job of everything.

[@james.d.8044]

Assembling the crank on the lathe was brilliant ,wow it was so cool to watch

[@markhensley9378]

Fantastic job on the crankshaft! Can't wait to see another video of this project. Traci makes some beautiful cupcakes as well. Have yourselves a great week.

[@danwolf307]

I am shocked that KZbin unsubscribed me! I can't imagine it's Tracy's cupcake's that they're upset about, must be the overlords don't like 2 strokes! Resubscribed now, thank you for the awesome videos Allen, can't wait for the next installment.

[@AllenMillyard]

Glad you’re re subbed 🙂

[@malcelwell7209]

Hello Alan you make me proud to be British, absolutely love your videos out of this world, you blow me away 👌🙏

[@andrewknightley6799]

Another great Millyard production watching a genius mechanic and Tracy making cupcakes what a treat.

[@is300glenn]

Talk about a skilled mechanical engineer - this guy is amazing!

[@Happyfacehotwheels]

I love the "anything is possible" mentality of your work. Thank you.

[@yorkshirelad3133]

19 minutes of my life that I glady don't want back, always great watching Allen

[@MegaDirtyberty]

Oh to ride one of Allen's creations and to sample Tracey's baking... you are a lucky guy Allen.

[@darrellmeganfoxall8830]

You've probably heard this so many times, but you are a very clever man. Love watching your videos👍👍👍👍

[@trevormartin5459]

What can you say?It's just unbelievable what Allen does.Fabulous.

[@Hungry_Hunter]

Tracey is a deft hand with the whisk and the thickness of that marzipan was perfect at 3mm. I would love to see her use all the cherries in her cup cakes that would be magic. We only have possums in Australia no squirrels mores the pity .The crank build was nice too.

[@MM_in_Havasu]

Excellent mechanical work on the 4 cylinder crankshaft, Allen! You make it look easy to do. Thank you for your usual great video content!🔧🛠⚙

[@GarryMcGovern]

Tracey is to cupcakes, what Allen is to engines.... I didn't know which one mesmerised me more!!! 😉 Another wonderful, wonderful video Allen - I've been banging around on a 30 year old 205 GTi this morning (trying to take a break from my own bike 'projects'!), and this was just the thing I needed for my lunchtime cuppa!

[@pauliebots]

Like a few others I was expecting some hacksawing, welding and grinding, didn't know the cranks went together like that. Pretty cool. I tell you another thing, it was nice to see you not babying the con rods like every other builder I've seen. They rap them in diapers and tape and rubber and Styrofoam etc. I never thought those little taps ever harmed anything. Thanks for posting.

[@doctordapp]

Thank you for showing 'how it's made'. Real interesting to learn and imitate! I will use the pinning method for the twin I'm building, thank you!

[@gianlucamammano3506]

You are genuinely one of the nicest men I have ever seen on KZbin. Your personality is just so genuine and I love watching your videos! This is the first one I have watched and I am excited for more.

[@AllenMillyard]

Thank you 🙂

[@ch0cchip704]

Ow my! engine parts, a amazing workshop and stunning cup cakes heads spinning i could imagine that crankshaft is better than it left the factory.

[@christianmccollum1028]

Thanks for showing the build, Mr. Millyard. You are a mechanical genius!!! Much Respect from Texas. 👍

[@reneetekanawa-hughes215]

Best engine building teacher out there 👌☝️ watching from the other side of the globe in New Zealand 🇳🇿 🇳🇿🇳🇿

[@johnjones4825]

Engineering and cooking lessons in one video. Brilliant concept, well done the Millyards!!

[@grenvillephillips6998]

I'm increasingly convinced that it is Mrs Millyard who is the mastermind behind these projects and uses fairy-cakes as a reward system to motivate and control Allen.

[@walkingpictures]

Fantastic work as always Allen,thankyou for the video and great to see Charley Weaver keeping an eye on you.Bonus Christmas cup cakes,doesn't get much better than that,well done Tracey...Just Perfect 😊

[@soundslikebstome]

Cupcakes and crankshafts....it doesn't get any better than that. Thx for sharing with us.

[@steveskouson9620]

So, I see this video about building up 2 cycle 4 cylinder bike engine, and I'm like YES! But, I see the Missus putting cherries and some mincemeat, in the cupcake batter. AWESOME on both fronts! Would have never thought about adding mincemeat to cherry cupcakes. Mincemeat is HIGHLY under rated. steve

[@nxr780]

Hi, my name is Flávio and I'm from São Paulo, Brazil. I want to congratulate you for the video, for the clean and equipped workshop, for your great work and for the video introduction of the scene where your wife makes the cookies. Congratulate her too, as they were very well done. A hug.

[@garymarklein4550]

I sure look forward to you and Tracy and the wildlife in the backyard a great relaxing video always and such love and brilliance

[@tonylittle2744]

Hand held electric drill. No centre punch such as far as I could see. Just bang the pins in. This man is a God.

[@redbeard4671]

I just found you when researching building custom engines from old Honda GL1200s, you are an inspiration, really impressive engine work and videography. Thank you for sharing.