It is probably a riding technique error but my Rev3 chain eventually saws a hole through my boot. The swing arm also looks polished in that area on both sides so I must hug the bike a little but never feel interference when riding. My feet are little so it is not a size issue. I had a leather patch sewn on but now it has sawed through that. Can anyone recommend a more permanent fix? Would some kind of plastic work?

I know of several people myself (size 11 / 48 boots) included who tend to rub the swinging arm with their heels. I have never had a too serious problem with boot wear but put a smear of car body filler on the swinging arm to stop that wearing.

Check you footrests are not drooping or bent back.

It may be possible to use the bolts (or longer ones) that hold the footrest hanger to the frame to attach a thin aluminium plate to keep your heel out.

Strange, but the boot is not the issue. Maybe a thick piece of plastic as a frame spacer to kick your foot out.

Interesting, the peg on that side was bent back a litttle. I straightened it and will give it a try. thanks

Find a place that works on horse saddles and tack. They can advise of a proper patch and also install it for you. Then, work on adjusting your riding position to keep those ankles away from the chain.