I recently acquired a 1948 Raliegh Dawn Tourist. The bike was sitting in a warehouse for 50 years and hadn't been move during that time.
This weekend, I disassembled the hub and gave it three kerosene baths. The first was dark and muddy, the second kind of gray, and the third one clear. I repacked the bearings and reassembled the hub. I then gave it a couple good squirts of Phil's Tenacious Oil.
I relaced the wheel and while spinning the wheel on the truing stand, I heard a light, but disconcerting, scraping sound coming from inside the hub. I removed the R.H. cone and the driver and gave the hub a spin. It sounds like the clutch is scraping against the planet body, but it could be the axle key scraping against the clutch; it's hard to tell for sure, but that's the area it's coming from.
How much oil is enough? I see a light coating on everything, but certainly there's not an oil bath. Is this the likely culprit, or something more serious?
The Strumey Archer hubs only require a few teaspoons of oil but you still need to grease any ball bearings. I recently serviced a 1969 AW and it was as good as new. Hopefully you checked the Sheldon Brown site http://sheldonbrown.com/sturmey-archer/aw.html
When you disassembled the hub, did you tear it down completely to look at the wear points or did you just pull the innards out and clean them as a unit? With a hub this old, it may have some parts that need replacement.
I tore the hub down completely and checked out the wear points. I have no reason to disbelieve the guy when he said the bike hadn't moved in 50 years; the rest of the bike is in pristine condition except for a little warehouse grime. All the gold and red pinstriping is pretty much intact, for example. The only thing I saw on the internal parts was varnish.
I looked at these comments and felt I hadn't packed the ball cage properly so I redid that and dumped another teaspoon of oil directly into the hub. I looked at Sheldon's page again and saw I completely muffed the cone adjustment so I redid that also. One or all of those things did it because the hub purrs like a clickety little kitten now.
Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Raleigh Pro, Trek Cycle Cross, Mongoose tomac ATB, GT Bravado ATB, JCP Folder
AW hubs need a bit of bearing adjustment slop. And specific RH cone initial positioning. Sounds like you dealt with these OK in the end. Andy.