The hub is adjusted correctly, there's no bearing play and the parts are all installed correctly. I don't have another bike here with a red band hub or I'd swap the internals over to see if made the same noise but at this point I'm at a loss. It's been a long time since I was on a bike with a coaster brake, and I'm certainly a good 250 lbs heavier than I was back then, but I don't remember one ever making this sort of noise. I've tried more grease, less grease, no change. I took the hub apart again and found nothing wrong, no metal, no shavings, just clean grease. It does stop, and I can lock the back wheel up but gives me the feeling that something is grinding itself to bits inside. It feels like I'm grinding metal to meta as it stops. The hub shell looks fine, (I've got a few others to compare it too as well), As soon as the brakes start to take hold I get a loud moaning, almost fog horn type groan from the hub. As I apply the brakes, the pedals kick back a bit before the brakes engage, the arm isn't moving on the frame at all. I put the all new internals in and I still have the same thing. I rode it over to a local bike shop and the guy there handed me a complete new inner works to install. Now all back together, it stops fantastic but it still 'kicks back a bit, and it sounds like a cow mooing when I apply the brakes. All the splines and internals look basically new. I cleaned the hub out with mineral spirits, and relubed with Park bicycle grease. I took the hub apart and other than it having what was likely 50 year old petrified grease inside it didn't really show any wear. When I first got it, the coaster brake would kick back a bit when trying to stop and wasn't very effective.
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I took the whole bike apart for a full clean and regrease. The wheels needed some truing but nothing major. The bike is pretty clean, not even a ding in the chrome fenders. I picked up a fairly clean old Schwinn Typhoon a while back out of a dumpster.
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