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Got a buddy at work rides a sweet custom fatboy. Got it exactlly the way you are talking.
His buddy hit a ditch and car the engine guard was tweaked and chipped the paint on the frame and the insurance company totalled the bike. He bought it from his buddy rode it home and did a bunch of work on it since he bought it out from the insurance company.
He said there was nothing to bad wrong with the bike but the insurance company felt the frame was compramised and did not want the liability of not replacing or fixing it so they totalled it.
My dad was in the same situation with his 1979 shovel when he got hit. They wanted to total it and it had a complete rebuild on the motor and tranny and only had 25miles on it as he was on a test ride suck. They said it would cost 5k to fix and they were totallling it he said the hell you are and fought with them and eventually he was given a check for 5k to fix it and kept the bike. Put a new front set of forks and tire on and some more chrome and she's fine.
IF the damage is what it appears to be and nothing more (no bend in the frame ANYWHERE, no flaked off powdercoat on ANY weld or frame member) a good man with a grinder and mig welder, can of black paint should be able to fix this.
I suspect the insurance company wants the frame replaced because it is difficult (read: liability) to check every inch of the frame to give it a clean bill of health.
An annular cutter (hole saw) or just a plain ole drill can remove a larger circle from the tab, allowing a welder to put a welded plug in place, giving same or more strength than what came out of the factory.
Again though, I cannot stress this enough, without KNOWING for certain about the integrity of the rest of the frame, the risk or liability would fall solely back on you.
maybe it's just a cali thing I have two friend that the ins co want to total their bikes for a broken fork stop. ins wanted to replace the frame on both but was to costly. oh both guys still have their bikes. on yours that little hole torn out can be fixed real easy. what part of so cal do you live in here in the san diego area any number of indy shop will fix that .........
It looks to me like you could weld 2 thick washers to each side of the mounting hole to reinforce the area. I can't understand why the insurance would want to total it. If thats the case let them total it and if possible buy it back and make the repairs yourself.
I would use plates, instead of washers, with a piece of pipe in between. Might have to use a longer bolt, but it would be solid. I think a good fab shop could do it for $500 - $1000
So what is the posibility of buying a new frame, strip all the parts off the old frame and replace it on the new frame with a clean title. DIY.
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Did they take the gas tank off and look at the frame under there? A lot of time the frame will get tweaked and you can't see it till the bike is stripped down.
Last year I was talking to one of the guys at the local indy shop and he was telling me insurance companies don't mess around with fixing frames they just buy new ones or they total the bike.
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