Hi,
I just bought a 2001 23' long Champion shuttle bus too. Mine is based on the slightly heavier duty F-450 chassis, and my hitch is bolted to a much beefier extension than yours is. What I plan on doing is get my nephew who is a certified welder to build me a hitch. The frame in my case is 42" apart, so it is a non-standard hitch. I could have ordered a kit from
ETrailer.com that can be adjusted from 30" to 44" wide, and then it bolted together, the cross frame is slid into the side mounts, then you would drill 1/2" holes into the cross piece, and install the included grade 8 bolts through the frame mounts and cross pieces.
However my nephew can acquire the 3/8" thick flat plate at his work, and cut a 3" square hole into the end of it, then punch 1/2" holes in the section that will bolt onto my frame. I will have 4 bolts into the Ford factory frame, and 2 more into the frame extension. The 3" square tubing will go from one side to the other, and a 2.5" square tubing in the center will hold the standard 2" receiver for my trailer hitch. I want to be able to tow a 10,000 pound trailer with it someday, if I buy a toyhauler travel trailer.
Because I will be making custom flat plates for each side mount, I can make them long enough to go to the factory frame, and then come rearward about 12" so that the cross member is only a few inches behind my bumper. Then the 2.5" bar that will go through the 3" crossmember will extend out to the edge of my bumper. Depending on the height of my bumper off the ground, I might cut out 3" square from the bumper, or mount it below the bumper. I still need to figure that part out.
You might want to look at this link.
http://www.etrailer.com/Specialty-Trailer-Hitches/Draw-Tite/41990-16.htmlhttp://www.etrailer.com/Merchant2/graphics/00000001/pics/4/1/41990-16_d_50.jpg
By using 16" long frame brackets, they can be mounted so that they fit on the factory frame, and extend rearward, and downward. Then the cross member is welded to these brackets by a certified welder. Or just go to a welding company that can built a trailer hitch, and they will say $300 installed, and you are on your way. . . The picture shows the 16" side brackets upright, I would be using them on the other side and sideways, so that they extend from the front of the chassis by 16" toward the bumper, and only drop about 3" below the frame level. Then install 6 bolts from the Ford chassis through these brackets, and weld in the cross piece. This hitch kit is about $200.
You might also be able to buy a 'kit' hitch from a place like U-haul. Problem is that it is a welded hitch, ready to install on a F-350 or E-450 motorhome, and is $367 for just the hitch. U-haul will take one look at your frame, and say 'no way can we bolt this 5,000 pound rated hitch onto this extension'. So you are going to have to seek out a pro welder anyway. I did price a hitch at u-haul for mine, but planned on building one that will be much stronger.
I also considered buying a used hitch from my local Craigslist, that is 43" wide, and looks like I could modify it to fit my needs, but it is 50 miles away, and $100 that I probably will not need to spend, when I can get the raw steel the correct size for about $50. And have my nephew weld it up himself.
Good luck with your project.
Fred.
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