My damage is on the frame headstock, dont understand what you are saying.

Right , taking the dog out now. When I get back I'll post up a pic.

Cheers
Ben

http://img506.imageshack.us/img506/7062/ally7sq.jpg

Pic on the left is a piece of Aluminium with holes drilled in them. I use that to make the lockstops operational with a GSXR K series bottom yoke. They were bolted at the headstock using the bolts for the headlight/clock subframe. Thinking about it it won't work 'as is' since it would probably be too thick.

The piece on the right is a strip of Aluminium which would have been another option as could be shaped to fit. Again probably won't work as very possible reduce the amount of steering on the left as well.

Now saying all that I think we are probably making thinks more complicated than it needs to be. IMHO your original suggestion of using chemical metal would work fine. Others may disagree :P

Cheers
Ben

I only need it to pass an MOT in the short term, longer term i will want it fixed properly.

File the lug on the frame nice and flat, weld a blob onto the lockstop lug on the yoke, much easier than ally welding, then file it down when fitted so that the stop is where you need it to be.

It doesn't matter where the extra material goes - on the frame or the yoke - as long as the steering stops where it needs to.