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Meet Maude, my "new" 5 speed, drum brake DL-1

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Meet Maude, my "new" 5 speed, drum brake DL-1

Old 10-16-11, 10:56 AM
  #1  
alr
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Meet Maude, my "new" 5 speed, drum brake DL-1

I have had this project in the works for well over a year now. And as of yesterday, I can finally say it is completed or very nearly so.

Here's a quick run-down of the changes I have made (and when I say I, I designed the project, collected the parts, and built the wheels, but a trusted mechanic executed the final result):

Wheels: Alloy rigida westwood 28 x 1 1/2 rims (Freemans cycles, UK) laced to S-A X-FDD and X-RD5 rear hub with Phil Wood straight gauge stainless steel spokes

Roadster chaincase (Yellow Jersey) and Flying Pigeon rear rack

S-A rod drum brake conversion kit (Ebay UK)

44 tooth Raleigh Heron crank (Ebay UK) and 22 tooth rear cog (gear inches: 35.2, 42.2, 56.3, 75.0, 90.1 and was previously 46 x 24 with gear inches 40.5, 54.0, 71.9)

Lighting: Busch and Muller Lumotec IQ Cyo R Senso Plus Chrome and Toplight Line Plus

Hebie bipod center stand

The rod brake conversion kit has to be tweaked in the front to work with the geometry of the arms on the new S-A front hub. The hub is being run "backwards" and the stirrup has been bent to make it reach at the correct angle. The rear rod was also lengthened to reach the rear brake arm.

The frame and forks has to be spread and the forks filed to accept the new hub.

The ride? It is eerily silent and very smooth. The brakes work extremely well and will be impervious to rain. She did not lose any weight in this conversion, but the slightly lower gearing than before helps climb more hills. The only thing I think I want to change about the current set-up is the fork crown light mount—it doesn’t work very well. I think the heron bracket needs to be put back on and have the light mounting there instead.







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Old 10-16-11, 11:22 AM
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Just awesome - I love the final look.

After you ride for a while, post back about those grips - I have some (probably cheaper knock offs) and find they irritate my hands after a while....
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Old 10-16-11, 11:47 AM
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Oh, those grips are the real rubber French VAR ones that used to be sold by Harris, but sadly are not any longer. They are squishy and dreamy. Not terribly durable though. I have had these for about a year or so, and there is a crack in the end of one.
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Old 10-16-11, 01:10 PM
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Boy, I really like the look of this!
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Old 10-16-11, 01:16 PM
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Hey, that's pretty!
I finally got my camera to work so now I can post some of my rod drum thingy. It's just a rod and drum kind of weekend.
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Old 10-16-11, 01:35 PM
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I love it!

Nice job.
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Old 10-16-11, 03:07 PM
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Beautiful.
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Old 10-16-11, 04:53 PM
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Dude! That's gorgeous and I love the double drums and creme tires.
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Old 10-16-11, 10:26 PM
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I also should have added some as found and how I had it for a year or so as a three speed. Here they are:

As of last week, it looked like this:

And when I first got it:
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Old 10-17-11, 02:18 AM
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Nice!!

Were the rims painfully expensive to have imported from the UK? You don't have to be specific if you are uncomfortable with that.
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Old 10-17-11, 09:18 AM
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Since the cost of shipping was slightly less than the cost of the rims themselves, I did not find it too painful. I thought it was fairly reasonable given the size of the package and the fact that they went on an airplane. Oddly, I no longer see the aluminum westwood rims on Freemans website. I wonder if they stopped carrying them? At the time I bought them, I was not planning to do the drum conversion-- had I planned that all along, I might have gone with steel rims.
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Old 10-17-11, 10:45 AM
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Very nice job on your DL-1! How does the front brake hardware attach at the fork? Can't tell from the side view. I have a ca.1980 Danish market DL-1 that I'd like to convert to a front drum brake. It has drum on the rear but the stirrup style in front.
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Old 10-17-11, 11:01 AM
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Looks wonderful! I'm curious on how easily the Yellow Jersey chaincase went on; I've never heard if it is easy or a lot of work.

Looks like you have the best of both worlds-cool older bike with great stopping power.
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Old 10-17-11, 11:50 AM
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Originally Posted by HercRider View Post
Looks wonderful! I'm curious on how easily the Yellow Jersey chaincase went on; I've never heard if it is easy or a lot of work.

Looks like you have the best of both worlds-cool older bike with great stopping power.
Thanks! Since I did not do the assembly myself, I would need to direct that question to my mechanic. He did mention that it was kind of hard since there is very little clearance with the 22t rear cog. The good news is that the bracket they supply with the case that mounts near the crank is not necessary since there is a mounting hole there in the frame, you just need to drill a hole in the case, once you have it all lined up. My mechanic did a very nice job-- he was complaining that the chain was still rubbing a little bit from time to time, but to me, it is imperceptible. That is why I like my mechanic, he is a perfectionist!
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Old 10-17-11, 01:28 PM
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Originally Posted by folderfan550 View Post
Very nice job on your DL-1! How does the front brake hardware attach at the fork? Can't tell from the side view. I have a ca.1980 Danish market DL-1 that I'd like to convert to a front drum brake. It has drum on the rear but the stirrup style in front.
Thanks! The trick will be to find another front stirrup adapter (I at one time had 3 of these, but have since sold off my surplus to other BF members). it works by attaching to the fork on one side, and the other side is free from the fork and extends a rod down to the drum arm. I actually have the hub and the front stirrup attachment on backward, and the stirrup is now bent too to make it work with the modern S-A front drum hub.

Here are a few images from flickr (not mine) that show it better (and not on backward):


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Old 10-17-11, 05:43 PM
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It occurred to me that someone should do this. And now you have. Excellent.

Send this in to the author of Lovely Bicycle. She'll appreciate it.
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Old 10-17-11, 06:24 PM
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alr, I have to say that is quite the beauty. Which tires are those? Welcome to the world of SA drum brakes! I've been shouting the praises of them from the rooftops for quite some time and have them on my Pug as described in this thread. BTW, the issue mention with the stirrup adapter perfectly describes why I am always reticent to let go of old parts.

What tires are fitted to the bike?

Last edited by photogravity; 10-17-11 at 06:25 PM. Reason: Siri
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Old 10-17-11, 07:33 PM
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Originally Posted by photogravity View Post
alr, I have to say that is quite the beauty. Which tires are those? Welcome to the world of SA drum brakes! I've been shouting the praises of them from the rooftops for quite some time and have them on my Pug as described in this thread. BTW, the issue mention with the stirrup adapter perfectly describes why I am always reticent to let go of old parts.

What tires are fitted to the bike?
Wow, your Pug is beautiful! Nice job-- how do you like the 8 speed hub? I am finding 5 so far to be plenty for this bicycle.

I can't say for certain how well the S-A drum brakes work right out of the box, as the shop that I bought my hubs from did some kind of service on them for me, which I think involved breaking them in. But they so stop very well, and it is comforting to know that this is not going to change with the weather.

The tires? They are Schwalbe Delta Cruisers in creme. I have to say that my initial DL-1 lust was spurred on by reading Lovely Bicycle and the choice of these tires are also due to her influence. The whole drum brake conversion thing came over time. I was at first just going to use the rod rim brakes with aluminum rims, but then I found the conversion parts serendipitously, or rather after a long time of hunting on ebay UK.

Last edited by alr; 10-17-11 at 07:37 PM. Reason: comment on pug
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Old 10-17-11, 08:09 PM
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Great job! The new and the old blends very nicely.
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Old 10-17-11, 08:23 PM
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I don't remember if I ever saw your bike, photogravity. Very nice. My Raleigh International will have a SA drum brake front and Shimano rear with cassette.
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Old 10-17-11, 10:58 PM
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Originally Posted by alr View Post
Thanks! The trick will be to find another front stirrup adapter (I at one time had 3 of these, but have since sold off my surplus to other BF members). it works by attaching to the fork on one side, and the other side is free from the fork and extends a rod down to the drum arm. I actually have the hub and the front stirrup attachment on backward, and the stirrup is now bent too to make it work with the modern S-A front drum hub.
air, Thanks for the brake info. I have a similar part off of a junked Dutch bike which I may be able to use. Will need to come up with a method to clamp it to the fork.
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Old 10-17-11, 11:03 PM
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Originally Posted by folderfan550 View Post
air, Thanks for the brake info. I have a similar part off of a junked Dutch bike which I may be able to use. Will need to come up with a method to clamp it to the fork.
You just might be in luck... the last part I sold off, the person did not need the fork clamp piece, so I still have it. I bet it could work with the stirrup thing you have pictured in your post there. Are you interested?
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Old 10-17-11, 11:26 PM
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Originally Posted by alr View Post
You just might be in luck... the last part I sold off, the person did not need the fork clamp piece, so I still have it. I bet it could work with the stirrup thing you have pictured in your post there. Are you interested?
I may be interested. Saw a brake clamp on UK eBay once that looked like it would work. I assume that your part must be similar. It's always great to get these old Raleighs back on the road!
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Old 10-18-11, 04:26 AM
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Originally Posted by alr View Post
Wow, your Pug is beautiful! Nice job-- how do you like the 8 speed hub? I am finding 5 so far to be plenty for this bicycle.

I can't say for certain how well the S-A drum brakes work right out of the box, as the shop that I bought my hubs from did some kind of service on them for me, which I think involved breaking them in. But they so stop very well, and it is comforting to know that this is not going to change with the weather.

The tires? They are Schwalbe Delta Cruisers in creme. I have to say that my initial DL-1 lust was spurred on by reading Lovely Bicycle and the choice of these tires are also due to her influence. The whole drum brake conversion thing came over time. I was at first just going to use the rod rim brakes with aluminum rims, but then I found the conversion parts serendipitously, or rather after a long time of hunting on ebay UK.
Thanks, alr. I really like the SA 8-speed hub a lot. It does require a small chainring which some folks dislike. Mine is 30t but is disguised behind the chain guard. Actually, you make a good point about the number of gears. I have a Schwinn Collegiate with a Sachs Pentasport hub and 5 gears is plenty for mot uses.

The drum brakes work so well on my bike I need to watch how hard I apply the brakes because of the power, though they are very easy to modulate atmo.

Those delta cruisers are great looking tires. I've been considering putting them on my wife's Linus but am concerned that they'll look horrible after one ride on the dirt path we ride most frequently. We'll see.
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Old 10-18-11, 04:34 AM
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Originally Posted by noglider View Post
I don't remember if I ever saw your bike, photogravity. Very nice. My Raleigh International will have a SA drum brake front and Shimano rear with cassette.
Hey Tom. The bike turned out better than I thought it would. I remember that you showed me your SA front hub at T-Town. I'm sure you're going to like it a lot. Now about that roller brake/cassette...
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