You might find someone keen to swap the mudguard. Rigid ones are thin on the ground. 

Hi Mate, cannot answer 1 and 2 but can offer some thougts on 3:

The fuel sloshes about in there and as you throw the bike into corners with your knee to the tarmac like Bazz Sheene some of the fuel on the right makes its way to the left etc. It is also a crude sort of 'fuel reserve' in that when it coughs and bangs to a stop through running out of go-juice on the left you can lay it over on its left side and get a bit to splosh over from the right. That might be enough to get you another 5 - 10 miles depending....etc

In my youth it was not un-usual to see people laying their bikes over and shaking them...sort of a Friday morning ritualistic tribal dance to get the last of it over to the left before the payday fill-up.

Despite all my efforts, shaking and swearing etc  I am always surprised at how much fuel is retained on the right. Bantam bikemanship....happy days.

Phil53 said
Hi again everyone... Things are looking a bit different now, frame repaired and painted, Footplate supports all welded on and secure , rear springs nearly ready to put on...tried the chrome paint on the spring shrouds... wasn't really impressed though..pictures really tell the progress.

Tank cleaned and sealed inside ready for painting........And of course a big thanks to everyone who has helped me with some questions I had. 3 more questions coming up though.

1) What stops the brake pedal from moving to the left on the footpeg bar? 

2)Surely there is a rubber washer where the front of the rear mudguard bolts on to the rear of the frame behind the engine ? Can't be metal to metal ?...

3) ( here's a dumb one) How does the fuel get from one side of the fuel tank to the other ? 

Thanks very much everyone again, great reading on this forum.

😢

OK Posted some pictures but it seems they are too big. Next project...learn how to make pictures smaller....  

Yes,

1. I had to put a washer on.

2. Purists may be appalled but I don't bother with this one. Certainly there is a gap; if I put a nut and bolt iin and pulled it up, the stud and rear plunger top mount holes wouldn't line up, or the mudguard be stressed. Didn't bother on the D3 I had either, mainly because I'd no idea there was even supposed to be a bolt there. Also, much much easier to whip off the mudguard if you have to.

3. What Sponge said.

4. There is no 4.

I disagree Sunny, I don’t think that there’s any way you can make that Indian guard fit and not look utterly ridiculous. It looks to be physically too big for even a heavyweight BSA. 

If it wasn’t so frustrating it’d be comical. 

In your position Phil, I’d use the rigid mudguard you already have, and keep my eyes peeled for a genuine plunger one at the right money. 

Firstly great progress, looks like you have made a nice job of the footrest repair.

That mudguard is terrible, radius is to large, if you put the two together I think it will be a long way out.

Rigid mudguard is you best bet, just check you have enough clearance on full plunger travel.