OK, spent another 2 hours with Welder Guy last night. He's going to have to start over from scratch. We got the hitch tucked in as far as humanly possible (snug against fuel tank shield & frame crossmember). Still couldn't get the cladding to align properly.

Our fall back position is to change from 2" stock tubing with 1/4" wall thickness to 1 1/2" stock tubing with 1/4" wall thickness. This should NOT significantly decrease the strength since we are WAY overdesigning anyway. The main reason that we were trying not to go away from the 2" tubing is that is what he had on hand. He'll be picking up the new tubing and tack a new copy together ASAP. Poor guy had such confidence in the last design that he actually cut enough tubing for 3 hitches. His plasma cutter is FUBAR & his welder is acting up so that's slowing him down too.

Wierd: I've sheered off two of the 10mm bolts on the rear of the cladding. Not sure what that's all about. I've learnt to get the cladding off in 10 min flat. WooHoo!!!