Has anyone done this befofe? Do you actually use the existing factory mounting points or does it require new holes drilled? If so do you have the close up shot of where the extra hole is drilled on the side? 

I'm going to do both bikes in my garage plus and my mates. So 3 in total.

Something like the one in the photo. 

Further to this, I'm aware this doesn't meet the nsw regulations, but my question is,  has anyone here have the first hand experience w the popo and how did you deal with sorting it out? Has anyone gone the extream of welding the piece back in to get compliance?  Thanks in advance gents.

I never had any issues with the police.  The worst defectable thing I had was a lay down license plate holder, where you couldn't really see the license plate.  Still I didn't have any issues, but I guess it depends on what cops you come across.

** I wouldn't recommend removing the front fender completely.  In the rain the water will spray off the front wheel straight up into your face.