Hello Beta,I can't help you much since I have a '74 750 K4, but I'll tell you some things that might be helpers.
My chain guard is factory original all metal. Even though I make concerted efforts to keep the chain oiled and properly tensioned, the chain has worn several spots of wear into the chain guard, one almost is on the verge of breakthrough.
I have read somewhere on this board that the original 750's (KO) had a chain guard that was at least partially plastic/composite, and that portions of that guard were wearing through and even breaking off. Honda then redesigned and went with metal and changed dimensions........ so the bottom line is Honda engineers had problems getting this right. Not trying to discourage you, simply suggesting this..........
Be more generous with your final building dimensions to allow as much internal clearance for the chain as you can get away with. No matter how well you keep the chain tensioned and oiled, it does flap around in there far more than you think it would.......
I hope this helps and gives you some more insight into your project. Good luck.......

~ ~ ~ jaknight ~ ~ ~