Twin disc conversion - Kawasaki S1 550 four

[@1gtd1]

I've often thought about adding a second disc to my front wheel. Having watched this video I now realise I'm never going to do it!

[@rikhughes6452]

Do it the easy but not as cool way put the second one 180% round so one caliper is forward one is back

[@Wingnut_Stickman]

Is there anything better than a new Allen video?

[@ParaBellum2024]

Maybe a new Allen _key,_ if the old one has become rounded?

[@dennis-nz5im]

Two stroke stuffing and Ave ,Peg and a couple other people

[@BitsAndBobs1]

2 new Allen videos?

[@thewanderin_rider]

Yep….. another new video 😁

[@kubaceg1]

New project from Allen with whole series of movies ❤

[@tlf.]

Measuring by eye and it manages to look factory new is very impressive

[@quartusbuys6831]

If it looks right, it is right.

[@rixogtr]

apart from that eye gouging porosity and unfinished welds it does look really good, it's impressive that there's no noticeable difference between the color of the weld and the fork material. I wonder what filler rod he used.

[@lonewolfandcub668]

Old caliper designs really show how much they have progressed. Still good though

[@Dave5843-d9m]

It will be stronger than the original but how much perfection does a mudguard bracket need?

[@SuccessShared]

​@@quartusbuys6831Amen to that! First lesson as a technical illustrator! I remember it well and it's surprising how it's still relevant today!

[@classicmusclecarexhaust1988]

Allen, the most encouraging thing about your videos is that the work you do is not with a 3D printer or a CNC milling machine, but with a simple shop, hand tools, a good eye, and a cup of tea. I can't tell you how inspiring that is to me.

[@keithammleter3824]

He does have the right equipment though - things that a lot of backyarders/hobby workers don't have - micrometer (which he winds in correctly, not with the barrel like a lot of KZbinrs), surface plate, slip gauges ... and a small but decent Colchester lathe, not one of those terrible Myfords a lot of Britishers seem to go for, or the even worse Unimat..

[@LessTimeThanYouThink]

Not to mention using the path and lawn and a Millyard foot clamp for grinding works. Brilliant stuff.

[@gazzafloss]

Allen you're a "master" of the hand tools, great to watch a craftsman working with simple everyday saws, files and power tools.

[@-IE_it_yourself]

you could build pyramids with the 90' when he was drilling the mud guard lugs

[@howder1951]

Very nice work on that fork, fitted and finished more like an artist rather than a mechanic. It always feels good to do a beautiful job like this, cheers!

[@WreckedRevival]

Your calm cool demeanor really makes for a therapeutic video to watch and the lack of music plus the inclusion of nature and it's sounds/creatures make for a nice touch. Aspire to one day be as knowledgeable in machining and fabricating as you!

[@althejazzman]

I totally agree. His videos are so technically interesting but so calming, it's like he has an infinite amount of time to make things.

[@davestrain9529]

@@althejazzman Times are TOUGH! I use it for Therapy.the soothing voice.... especially Tea time, when the Crumbly cakes ( and Robins come around) in the latest Video. Dave Boulder CO USA rd350, TRIUMPH Tbird Sport , KTM 300 XCW

[@camperp195]

Always therapeutic watching you work allen,your engineering genius is on another level 👍

[@davestrain9529]

Times are TOUGH! I use it for Therapy.the soothing voice.... especially Tea time, when the Crumbly cakes ( and Robins come around) in the latest Video. Dave Boulder CO USA rd350, TRIUMPH Tbird Sport , KTM 300 XCW

[@realemonful]

That's just pefect lol

[@computername]

It's engineering art. Non-mechanical people don't really understand just how amazing it is what you do. Before this channel was around I would speculate with friends what high-tech machinery would be involved in making these bikes. But it's made with a hacksaw and a Bantam. Thank you so much for letting us see you work your magic. The fact you're sharing your processes with the world should be an inspiration for what's possible with simple tools but ingenuity and determination. I think this much overlook in our tech-centred world. Thank you!

[@chrisharper2658]

Allen, you never fail to impress. And it's always nice to have a cameo appearance with the wife.

[@nv1493]

Love these videos. No stupid background muzak. No gimmicks. No history of the motorcycle. No self-aggrandizement. Gets to the point, beautifully edited.

[@AllenMillyard]

Thankyou 🙂

[@tjroelsma]

The mark of a true craftsman: making difficult jobs look easy.

[@joseywales3789]

Allen, not only brilliant Engineering but we got to see Charlie Weaver and the Swiss Army Knife! Just missed the Barbeque and we'd have had the Hat-trick (Greta on the Erickson would have been the Royal flush!) But unless you needed to preheat the fork leg prior to Welding, it wouldn't be needed. Thanks Tracy for the Tea, perhaps a cherry cupcake 🧁 would have gone down, nice... Just a thought 🤔😁 Thanks Allen.

[@stephenrice4554]

Clear , easily understood description , and wildlife moments . Marvelling at Mr Millyards dexterity with a hacksaw and hand tools to get an accurate and neatly finished modification. Impressive.

[@lyndonwebber1389]

If Alan was our teacher at school, who would of turned up more and actually learned something interesting and useful? Always a pleasure Alan 👍🍺

[@matthewrooke386]

I always learn something from Allen’s videos - superb as usual thank you.😊

[@CONEHEADDK]

I love them. And I'm impressed. But they also always depress me a bit, bcz thet keep rubbing my nose in, that I shouldn't have believed all those know-it-alls, who told my, when I was a teen, that "that's impossible", "You can't weld a crank", just to mention one of the lies..

[@Ravan_Caw]

👍🏻👍🏻👍🏻

[@GT380man]

@@CONEHEADDK No, THEY can’t weld a crank! Nor do you need to with Allen’s builds of fully pressed up cranks. Extra pins & flywheels and off he goes.

[@lovemore4229]

It has the same feeling as watching a 1970's test cricket match, cheers Alan love your vids.

[@johnpartridge7623]

That Fork Leg looks genuine Kawasaki, a good piece of Engineering Allen, spot-on 👍👍👍👍👍👍👍

[@leslieadams5507]

Ladies and Gentlemen it's as easy as that. 😊 Another masterpiece by Alan.

[@louisjones2653]

Never seen someone so precise with a hack saw!

[@rollingthunder45]

Excellent, a walk in the park for a man of your talents Allen! Enjoyed this one. 👌

[@BMW7series251]

Just a joy to watch Allen. What a bummer, no cupcakes!!? Thanks as ever for posting, best regards, John.

[@dsofe4879]

Love how you covered the machining in more detail, really interesting!

[@johnb5519]

Amazing how you make it look so easy. You're a real inspiration to all us do it yourselfers.

[@shannonharris2816]

Allen, you are the apotheosis of 'Zen and the Art of Motorcycle maintenance'.

[@1234567marks]

I converted my CB750 SOHC to twin disc, fortunately Honda had the foresight to include lugs on the other leg, so it was just a matter of trimming them to the correct length, far easier than what Allen had to do, it makes a massive difference to braking power, twice as good you could say!

[@stevefletcher2334]

a gentle soul with the skills of a master craftsman

[@franklake2073]

Brilliant engineering and an excellent, well shot and well explained video. many thanks!

[@markhensley9378]

Great job making the caliper mounts! Like everything else you build, it looks like a Kawasaki factory built unit. Thank you so much for taking the time to film this process. Enjoy your weekend.

[@CaptHollister]

The incredible attention to detail: did everyone else notice the "550-4" stamped at the bottom of the new, modified fork leg ?

[@Hoggdoc1946]

Once again Allen is brilliant with his fabricating skills.

[@markrivett9493]

Never cease to be amazed by how you make quite complex jobs look easy. Seriously talented.

[@nobbybennett575]

Clever man. Never get tired of watching Allen work.

[@ricvis44]

Wow! I was wondering how you were going to make the second break line. So simple! I would’ve never thought of that probably. 👏🏻👏🏻👏🏻

[@paulcasey5204]

Ditto. And then felt a bit foolish when it was so simple.

[@prillewitz]

Banjo solves everything!

[@dhcrouchmarineltd3049]

Honestly, just pure joy Allen. Thanks for making these.

[@keithgarland3404]

Thanks Allen, another job very well done, the ceramic coated callipers looked smart.

[@mitcheloo2632]

Every time I see your work I'm just impressed at what you can do in a shed, my respect!!

[@davestrain9529]

and!!! The ICHIBAN MOTO sticker..Sense of Humour!!

[@AussieMaleTuber]

The only thing better than a Kawasaki is... an Allen Millyard Kawasaki, and watching it being built. Philosophically, a Millyard is the Greek Form of a Kawasaki!

[@xavey123]

The Kawasaki DemiGod in action!!! Fantastic work Allen. Looks and functions better than the factory version. Thanks a lot for the amazing video. Look forward for more.

[@RalfyCustoms]

Hi Allan, hope you and Tracey are keeping well buddy, I'll watch this in a bit with a brew and a nice cupcakes 😊

[@jjrider6758]

Fantastic job Allen, I could watch you videos for hours (if I had the time !..) I just wish jobs like this were as easy as you always make them look !!..

[@grenvillephillips6998]

Some excellent camera work there - much appreciated!

[@G58]

Indeed. I noted that too. Allen’s cinematography is always good, but this one was excellent.

[@oddsends6048]

This world is going insane but watching your video drops my blood pressure by half.

[@scooterwoodley195]

I haven’t been this relaxed since Mr. Rogers, circa 1973

[@wollaminfaetter]

The sound in your videos are amazing. I'm really pleased with that.

[@redfishross]

The man is a wizard.

[@stevegordon2032]

Utterly amazing to watch such skills. Smashing video and commentary as well. Allen you are a genius.

[@TheDaf95xf]

Hi 👋🏻 Alan from Brugge in Belgium 🇧🇪 Just retired for the evening so nothing better than watching one of your excellent videos 👍🏻 And you got a brew from the misses but no cake 🍰🤔 The Robin was lovely to see too 👍🏻

[@ajl9491]

Kawasaki graphics and big non drilled disks take me right back to late seventies when I would ride my S3 bike in snowstorms to college!!!(Montreal CA)

[@mortdk]

It's always a joy to follow Allen's creative abilities unfold. Excellent and top notch quality 💥. I actually did something similar (although not on the same professional level) in 1993 with my 1983 Yamaha XS400 DOHC (12E). It also had a single front disc only. But the front wheel was the same as found on a XZ550 which had twin front discs. And since the tap holes for the screws for the brake disc were already there, the conversion was quite straightforward. To fit a second brake caliper, I used the lower front legs from a XJ550. They had the same fork stanchion diameter (35 mm) as my XS400 DOHC had. I then acquired a set of RD350/XJ600/XJ900 slotted brake discs. Braking was improved with the twin disc arrangement - no fork twist if firm braking was applied. Which could happen with the single disc only. And optically it looked great! One drawback with the twin disc arrangement though was that the unsprung weight was higher. So in some occasions the front suspension actually felt a little harsher than with the original single disc layout.

[@davelawrence594]

You literally are like reading the old Haynes manual from back in the day but a video version hehe? 😁 Always amazing to watch you work on literally anything Alan!!! 👌🏻👍🏻

[@dennis38y]

Brilliant once again Allen. You managed to make it look easy using your logical and steady approach ! Thanks for sharing

[@minnesotatomcat]

You made my Friday night Allen! Very nice conversion, I’m sure you’ve got all the stopping power you could ever ask for now. I love that 2 tone green paint scheme on that bike, always good to see it out 👍

[@TheHalloweenmasks]

The two tone green is my favourite, my 250 is candy wine🙁

[@martinhaag3669]

Very nice work Allen. On my S2 I had to change the master cylinder because I used other calipers. The only thing is I am missing the fourth cylinder I 💕 the sound of your bike more then I can express here. Thank you so much Allen

[@davidwilliams5942]

Having started my engineering apprenticeship in 1974 I really enjoy your videos for there old school skills also I just noticed that Charlie is a Isle of man fan that made me smile 😊

[@G58]

Same here. But I collected half decent grammar skills before leaving school 🙄👀🧐😎😜🙈

[@loddude5706]

@@G58 - A shame tact didn't lodge somewhere too : )

[@G58]

@@loddude5706 From who’s perspective? It was of a grown up bit of humour. I had no idea you were such a sensitive soul 👀🙄🧐😎😜

[@loddude5706]

@@G58 - Schadenfreude is 'grown-up'? : )

[@RestorationWatch]

I had dual discs on the H2 750 Mach IV that I bought when I was 18 years old. I fitted aftermarket exhausts and had the motor rebuilt by the local Kawasaki dealer. I also had the paint refreshed. I loved that bike.

[@malcellison8831]

Mesmerising 😊 It’s always fantastic to watch you work and listen to your calm, gentle narration. Thanks Allen. Superb work.

[@davestrain9529]

Times are TOUGH! I use it for Therapy.the soothing voice.... especially Tea time, when the Crumbly cakes ( and Robins come around) in the latest Video. Dave Boulder CO USA rd350, TRIUMPH Tbird Sport , KTM 300 XCW

[@Mr-ue2ul]

Perfect Friday eve. Wife out and abit of Allen Cheers mate

[@rdaystrom4540]

Very nice twin disc conversion. Modifying the fender supports was pure skill and artistry. Love watching all your videos.

[@leslieblackburn986]

Great to see that Allen's excellent engineering hasn't been affected by his crashing a 70s Triumph chopper.

[@AllenMillyard]

🙈 ill never live that down !

[@chrisstephens6194]

No Millyards were hurt during filming

[@CaptainDangeax]

Nice job. Each time I ride an old motorbike from the previous century, I can feel the progress made in braking power and ease of use

[@simonlunt353]

You always make it so easy Allen it is always a pleasure watching you 😊

[@vincentwhiteman6433]

Great to see you back Allen, a brilliant video as usual and a first class job. Just love it. 👍

[@gerardcullen5131]

Poetry in motion is to watch Alan working on any project

[@vitorantonio8049]

a channel rich in information and different projects 🤩 👏🏿👏🏿👏🏿👊🏿✊🏿👊🏿✊🏿👊🏿✊🏿

[@ducatobeing]

Yet again I stand in awe of this zen master of the workshop! Calm, restful tones which deceive you into thinking that you too could do this. No, you'd end up with a nervous tick and twenty-two miles of swarf, and in the end, no result. Alan you amaze me! Just don't stop.

[@bongosock]

Really good production on these videos, by the way. Really good angles and editing - nice work :)

[@alextripp1230]

Hi Allen, very nice work on the fork leg as indeed the whole conversion. I had missed the grass/trainer vice along with your skill with a hacksaw, both brilliant viewing btw.. Great video as always. Alex.

[@GarryMcGovern]

Allen is like Paul McKenna for bike engineering geeks.......... I'm in a total trance here now watching this!!

[@hikerrobot]

Very entertaining. And not a torque wrench in sight when tightening. Love the little touches in the video too, like the birds and the cuppa. Great video

[@paulnelsonisnotabot]

Camera work is getting better every video, lovely watching you work

[@vincentscott6168]

22 minute video went by in what felt like 2 minutes. Always sure interesting. Thank you Allen.

[@TheSillybits]

I enjoy your videos very much thanks! You are a great craftsman and entertaining too. Your videos remind me of my father and grandfather who were great craftsman too and by whom I was taught practically everything I know (not pretending anything though). So many cars and motorcycles were restored and driven and sold, I really miss that time but looking at your fantastic projects carried out in your little shed brings that time to mind again. Absolutely fantastic.

[@bobhorne8410]

Just stumbled on to this new Allen Millyard video in my KZbin feed.. I’m really pleased with that!

[@rednelli]

Allen, how nice to see normal hand tools in action. And a man who knows how to operate them. Thank you. And from experience - I would still suggest removing the air at the clamps. To air out the whole system. BR from Poland.

[@GraemeRobinson]

Fantastic. I learn so much just observing your work Allen. These videos will be a real legacy of your skills.

[@JohnMason8183]

First time I've seen a double-banjo bolt like that. Great video.

[@teneretraveller8980]

Beautifully done. And great videoing and editing,too. Pure, motorcycle therapy. Thanks for sharing. Safe, happy travels 👍

[@martyndunn1905]

Love watching these videos, I agree your an artist aswell as a mechanic.

[@petemoore6590]

Really enjoyed seeing this Allen, especially the KH250 brake calliper. I bought a new KH250 in 1978, I used it daily even into the wintertime, eventually the front brake caliper piston seized up. My bike was still under warranty so took it back to the dealers for repair. Due to all the strikes that winter it took weeks to get hold of the new caliper seal, I was reduced to getting the bus to work, and even had to walk the 7 miles home in the snow once due to a bus strike! Thanks for stirring up those faded memories.

[@rolfpiotrowski4325]

Hey, Alan! Good idea to make the old widowmaker a bit safer! Happy Easter to you and your family! 😎👍

[@stephenwilliams926]

When I see a leadscrew spinning that fast @ 5:44 I get a shiver down my spine. Good video.

[@TheMasonjarz]

I was very pleased to find a new AM video this morning. Terrific job! There is no one I enjoy watching more. Thank you

[@vidvidbiker]

Thanks for making this video. All the salient steps clearly shown - brilliant.

[@johnfrench9608]

Allen your prowess with a hacksaw is just amazing.

[@richardphillips3303]

Absolute mastery of engineering and the camerawork is none too shabby! 😊

[@TomBudin]

love your work allen, always learn a lot from your videos!

[@stigbengtsson7026]

The absolute master in his workshop 👍😎👍. So great to be able to se and learn. Thank You. Best whishes from Sweden.

[@jonathangehman4005]

There's a couple of neat projects I've finished for my cars under the influence of Allen's vids. I bought 2 old early 70s Honda bikes, CB750 and CB350 to mess with arter swearing off motorbikes after my daughters were born, they're all grownup now so, you know, time to do like Allen does

[@firsteerr]

i like to see a man use the traditional "plimsoll and knee" vice to hold down his work

[@magpie6648]

Engineering at it's finest, Hacksaws and files😊 Great stuff Allen.. top work, great videos....😉

[@johnfleming3212]

Hi Allen, takes me back to my engineering apprenticeship at Laurence Scott's in Norwich, I did not realise how much engineering knowledge was imparted into a 16-20 year old. Not to the same level as you though. Amazing video

[@Gobbbbb]

There's nothing more satisfying when a job you do just works lovely, these videos are so therapeutic. Great stuff Allen hope to see more videos from you soon.

[@tudomerda]

I like how you carefully close the workshop door so as to not make a noise then switch on your angle grinder :-)

[@bjoernandersen8287]

It's unbelievable what kind of modification Allen manage to make with simple hand tools, a lathe machine and a ton of experience. A nice cup of tea is the bonus for well done job. No cupcake this time. Thank you for another superb video and looking forward to the next. :-)

[@lonewolfandcub668]

Your videos always inspires me to get going in my workshop on the bike.

[@ninja12lawbreaker]

I am a bit wiser than 20 minutes ago, fantastic engineering as always Allen

[@andyh4449]

No cake Allen !! Can’t believe it 😊

[@hotoilhands]

I did this with my Canadian spec XS650, easier to do since the fork was already set up to accept another caliper. It was amazing the difference a second disc made to the stopping power. Well worth the effort. That was a fun video to watch Allen. Thanks.

[@colindowd3892]

First class job as always, wouldn't expect anything less from this man.