DIY Gold Star style chain guard?

[PDMiller]

My RGS lookalike (sort of ) rebuild continues and as my kid's inheritance shrinks at an alarming rate I'm presently awaiting the arrival of the correct rear brake drum / sprocket. Looking ahead I see that chain guards are like hens teeth and having heard horror stories about the Indian efforts I'm wondering if I can fabricate one till a decent original comes along. Obviously it would only need to be good enough to paint and not to chrome plate.
Just wondering if anyone has had a go at it. The only difficult  bit would seem to be the compound curve at the wheel end but surely there must be a way to achieve a reasonable result.
Now where's that book on English wheels and metal shrinking techniques?

Cheers

Pete

[RichardL]

Start with sheet metal.
, then, some  .

Richard L.

[Steverat]

Hi Pete. We made a chainguard recently from some remains picked up at autojumble.  There is plenty of B31 tinware around (in awful condition) which is cheap and can be a good starting point. Chainguards tend to get mangled. As you say, the back end curve is important to get right, but you can fabricate the rest onto it with a welder. VMCC Autojumble at Shepton on 9 March could be a place to go in the SW, if you don’t have anything by then, let me know and I’ll have a look.

You might also find something Indian on EBay.

Steve

[Seabee]

I recently purchased an Indian chain guard. It was pretty raw with some serious grinding marks to take care of, but the biggest thing that needed correcting was that the cut out for the transmission output shaft was on the wrong side. I cut it out and welded the piece back on the outer side of the guard. The holes were in the wrong spots, but I welded them up and drilled the correct locations. The metal was pretty straight.
This sounds like a lot of hassle, but for $60.00 I don't mind. I couldn't find a decent original. It seems to be proportionally pretty close to an original. The other guard in the picture is a cut down guard that was on my SR. I actually think it might have started life on an A65? It fit close enough to do the job.
I've entertained the idea of putting on a fully enclosed set, but there appears to be many opportunities for frustration and leaks!

[Swarfcut]

Hi  PD.

 Along time ago, before autojumbles, swap meets, online choices etc a fella by the name of Robert Drury started a kitchen table business producing the simple bits that had rusted away...chainguards  a speciality.  I bought two, back in the mid 1980's.   His technique was to make a  symmetrical  sheet metal blank, folded down the mid line to form the top straight of the guard. The flair at the back was formed by folding the oversized rear edges towards each other, overlapping them and spot welding together. Rough edges ground off, supplied unfinished, in the raw, they were of very good quality, and great value. Strictly low tech, backyard engineering.

  He appears to have been very successful, "Robert Drury Quality Products" is  now trading as "Robert Drury Precision Engineering" in business in a big way with a very specialised product portfolio. No cheapo chainguards now.

  So, adapt something to fit in the short term, keep looking in the usual places.  Buying a new pattern guard from India carries the usual assurance on a quality first time fit. Or have a go at making your own.

   If you go down the homespun route, cardboard templates are the way, only cut the metal when you are happy with the template.

  Look away now if easily offended....Newish old 40 gallon oil drums (a very reliable source of sheet steel) and scrap washing machines are the sort of material you can play with. Cuts with a well oiled jigsaw, even easier with a plasma cutter.

 Swarfy.

[Angus]

Pete IF it is of any help you are welcome to the below for cost of postage or collection (Suffolk). It came of the A7 years ago. It was chrome a bit rusty now a but could be a donner part. I hate to throw stuff away.

[PDMiller]

That would be great Angus, thanks. I'll send a PM with address details and could send a cheque or bank transfer, whichever suits you best.
will keep informed if I end up with a precision component .....or a garage full of twisted metal   

[Angus]

Its as it came of the bike 30 years ago and then sat in various boxes since. I not cleaning it  .
I will pack it up and go get a price for sending it and update you via PM.