The Schwinn lightweight that never was.

[Schwinny]

I think you're somewhat hampered by your choice of frame. I'd look at something like a 1960s Racer frame, or a Collegiate, etc. Granted it's heavier and welded, but the dimensions open up many US-made parts from the 1950-60s like forks, stem, bars, hubs, etc. Part of the problem with the frame you've selected is that it came from a time when Schwinn was sourcing more and more parts to fit it from foreign sources.

If you wanted to go all-out, a New Departure Triple Speed rear hub would be a US-made hub with gears. Otherwise, the Bendix manual or kick back is OK. I like the manual better. Your choice of front hub is good. I think Schwinn-built caliper brakes are also a decent enough choice for the front. Back could be the coaster brake.

Rims, S6 or S6 stainless. Spokes can be Torrington (Dave Stromberger was selling Torrington sets for S5/S6). Tires will probably be Kenda, but it's a small point - not too many choices in 597 size. However, some of the older Sun rims were USA-made. Perhaps there's something like a 650A Sun from when they were made in the USA.

Bottom bracket would be classic one-piece Schwinn if you go with the Racer type frame.

Brake housing and cable would have to be old stock, I believe. Most are made in China or Taiwan now.

Truly, I'd be open to any frame. It's just this one was free and it looked like a size to fit many of the parts I already have. I also imagine the finished bike should be of a quality level of at least a Continental. If I can get an appropriate fork I think this is a good frame for the job. Hand made American, and all that.
Seems it's a 24" frame and my old shoulder Schwinn lightweight forks must be from 23" frames. The ole' pre 70' to post frame sizing differential.
This one is 23" at the top tube, the other ones 23" at the top of the seat tube.= One inch difference.

 

[cyclingday]

Too bad it's got an English Freewheel!

Oh, Contraire!
It’s got a built in Schwinn proprietary freewheel.

 

[WillWork4Parts]

Oh, Contraire!
It’s got a built in Schwinn proprietary freewheel.

The last hi/lo hub I had on the stand had one of these "The Villiers" freewheels. If it is the free-hub body type hub, yes it's USA made, by Schwinn....or it's one of the Unicorn hubs that I haven't seen yet! I've seen postwar catalogs that call out large flange drum hubs "for use with foreign freewheels" but never seen that threaded hub shell in person to say what freewheel it came with.

Please share photo close ups of the freewheel if it is stamped Schwinn or something other than The Villiers.

 

[cyclingday]

Note;
5879A / 5826A

 

[Schwinny]

The last hi/lo hub I had on the stand had one of these "The Villiers" freewheels. If it is the free-hub body type hub, yes it's USA made, by Schwinn....or it's one of the Unicorn hubs that I haven't seen yet! I've seen postwar catalogs that call out large flange drum hubs "for use with foreign freewheels" but never seen that threaded hub shell in person to say what freewheel it came with.

View attachment 2126227

View attachment 2126228
Please share photo close ups of the freewheel if it is stamped Schwinn or something other than The Villiers.

Strange how things progressed.
Schwinn followed a lot of the English and French innovations early on. Even the first Paramounts were put together with English Walton & Brown fishtail/keyhole lugs found on many early English bikes. I've got a Villiers 20t on my 31' Armstrong. I've taken apart and serviced several old English freewheels and all are very different. My Villiers is one sided. Has the bearings on one side and floats on shims on the other. Depends on the chain tension to make it spin without scrubbing the inside. A TDC I serviced had 8 balls on each side separated by curved bars in the race channels. It growled at all times.
Weird tech going on back then.
What im saying is that I'm pretty sure Schwinn was copying many of the English manufacturers in almost everything having to do with lightweights.
Even the Schwinn drum hubs are suspiciously similar to English of the day

 

[WillWork4Parts]

View attachment 2126256

Yes, correct, but please forgive me if I'm seeing this wrong, the picture you posted looks like the bike has the large flange hub and the tell tale signs of a freewheel, not the large cog on the Schwinn free-hub type setup.

 

[cyclingday]

It’s kind of hard to tell from this picture, but it has the single cog that threads onto the freewheel body that is housed in the hubshell.
This hub was first introduced in 1940, and does resemble the type being used in England at the time.
But it was a proprietary hub that was exclusively made by, or for Schwinn here in America.

 

[WillWork4Parts]

View attachment 2126260
It’s kind of hard to tell from this picture, but it has the single cog that threads onto the freewheel body that is housed in the hubshell.
This hub was first introduced in 1940, and does resemble the type being used in England at the time.
But it was a proprietary hub that was exclusively made by, or for Schwinn here in America.

I can see it now! Its the previous photo that looked like a separating line between freewheel and bearing race, then thread on area. Must be a machining line on the cog making it look like a freewheel.
The larger threads of the Schwinn free-hub body doesn't help the 2 speed requirements of this thread's build, but the green on that bike is be-A-utiful!!

 

[SirMike1983]

I've used BSA and Birmingham Phillips parts to service early Schwinn cottered bottom brackets when I did not have a direct Schwinn replacement. Schwinn Built brake calipers can be repaired using certain Phillips caliper parts from that same period. Schwinn used Phillips brake levers and calipers for a brief period in the 1950s.

I would not be surprised if Schwinn used or copied Birmingham crank parts. The oval profile arms look very much like older BSA, Hercules, and Phillips cranks.

Prior to 1960, English bikes and designs dominated the small American market for quality touring bikes for adults. After 1960, continental influences gradually increased.

 

[Schwinn Sales West]

Too bad it's got an English Freewheel!

?? I don't believe I've seen an English freewheel that looked like the freewheel built into a Schwinn Drum hub.

I also agree that it is very likely that some of the early three piece cranks/arms, even the Paramount parts were sourced from England.

John