This aint overkill is it? Headache Rack.

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I already posted one pic in another thread, But here is more of it.Headache rack for my GMC K1500.Laying out the slats after tacking the frame up. Top capped off.Welded out and bed rails and gussets added. 140 damn 1/2" welds on those uprights.  Gratuitous weld bead pic.  Frame is made out of 11ga 1.5 x 1.5 and 1.5 x 3 tube. Bed rails and gussets are 1/4". And the slats are 3/16 x 1" and 3/16 x 1/2" flat bar. I was gonna do just expanded mesh, but didnt have enough and didnt want to wait for it to come in. Then I thought about doing some kind of cool spider web out of round rod. But again, not enough material and I dont have a roller. So flat bar it is. I havent weighed it yet, but it is pretty beefy. The plan is, have this on top of 11ga 2 x 2 angle that runs the full length of the bed with D ring tie down points. And then an aluminum tool box on top of the headache rack rails. I have to modify the lid of the tool box to clear the gussets and the uprights of the rack. But If I bolt it right I should just be able to remove 2 bolts from the box and still have the rack and rails.If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Not at all,  nice welding too!Farmer2Hobart Champion EliteMiller S-32p 12Lincoln sp175tLincoln 225 ac tombstoneHarris oxy/aceteleneMakita grinders/chopsawHypertherm Powermax 45
Reply:That looks great!  If things get hairy, that thing will stop an RPG TxDoc's Photos Lincoln SP175 PlusLincoln Power Mig 256Lincoln 250 LX Spool Gun Lincoln Precision Tig 225 Hypertherm 600 KMG 2x72 Belt GrinderBaldor 812RE Grinder
Reply:Nice build!!! Mine is similar in design but I'm making an bottle attachment then can be put in out with a pin for my cylinders. Then a back rack piece that can be installed when I pick up steel over 10'.
Reply:I would like to see how you are going to mount to truck bed rails that's where I haven really looked at for my truck. Keep us posted!
Reply:hard to tell if it's overkill. depends on what you're carrying. if the material you're hauling could slide inside the openings during (god forbid) sudden impact or crash then it's under built. otherwise you're good to go. imvho of course.i.u.o.e. # 15queens, ny and sunny fla
Reply:It certainly looks nice!  Much more uniform welds than I'm capable of sometimes.As far as too heavy............11ga tubing is probably right on, the bed runner is appropriate, but the flat is pretty heavy per lineal foot, and you have a lot of lineal feet of flat  Although, the flat will really be nice when the sun is at your back, and trying to shine on your neck (something I hate on a hot day)"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Now pay to Powder Coat it!Seen as you done such a NICE job building it!
Reply:Originally Posted by GavoI would like to see how you are going to mount to truck bed rails that's where I haven really looked at for my truck. Keep us posted!
Reply:Super nice!
Reply:Originally Posted by GavoNice build!!! Mine is similar in design but I'm making an bottle attachment then can be put in out with a pin for my cylinders. Then a back rack piece that can be installed when I pick up steel over 10'.
Reply:would only be overkill if the tube was 3/8" wall. looks very nice.
Reply:Do you have weep holes in all the tubing?  I ask because the previous owner of one of my trucks had a headache rack installed on the flat bed.  It was similar to yours and all the tubing was split from water getting into the tubes and freezing.  The tubes were all capped or fully welded joints and they looked sound.  Didn't seem to matter, although the vertical tubes were the worst.  When I cut the frame apart water poured out of some of the upright tubes of that old rack.You can fill the weep holes with a dab of silicone that'll pop out if water gets in and freezes.  Just a suggestion before you paint it.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Originally Posted by A_DAB_will_doDo you have weep holes in all the tubing?  I ask because the previous owner of one of my trucks had a headache rack installed on the flat bed.  It was similar to yours and all the tubing was split from water getting into the tubes and freezing.  The tubes were all capped or fully welded joints and they looked sound.  Didn't seem to matter, although the vertical tubes were the worst.  When I cut the frame apart water poured out of some of the upright tubes of that old rack.You can fill the weep holes with a dab of silicone that'll pop out if water gets in and freezes.  Just a suggestion before you paint it.
Reply:Looks like a giant headache to me... Ba dum tisssBut no seriously it looks pretty awesome to me! Good job.Thermal Arc 252iHobart StickmateIf you aint burn'n you aint learn'n.
Reply:All done. Just gotta take the truck into work tomorrow and bolt it on.Decided it was too much a hassle to modify the tool box so I could have it too. So I had to fill in the space where it was gonna be.Weep holes drilled. Thanks A_DAB_will_do. All painted up. Was gonna just bolt it to the side rails. Screw bolts. I am a welder right?  Well and the fact one of the bolts on the rack was gonna hit right in the front stake pocket.  The cross piece in the back will get cut off, just for support and to keep everything all lined up. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:larp; looks even better with the paint on it.i.u.o.e. # 15queens, ny and sunny fla
Reply:Dang nice work. I esp love the horns to keep stuff on top from falling off.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Originally Posted by docwelderlarp; looks even better with the paint on it.
Reply:Looks great. Very sturdy. Your welds look really good too. Enjoy.
Reply:Originally Posted by jeff scottLooks great. Very sturdy. Your welds look really good too. Enjoy.
Reply:Looks really good! Love your sig line too! Can't wait for pics on the truck.
Reply:Originally Posted by Canadian WeldingLooks really good! Love your sig line too! Can't wait for pics on the truck.
Reply:Good Work!!Idealarc 250AC 225SVictor OA-older made in USA stuff.And a crap ton of other stuff.
Reply:Certainly not overkill! Looks awesome! How about some LED's in it? I’m just happy to be here!MOAR LIGHTS!!!! ~1987 Lincoln Sa-200~~1978 Miller Big 40~ (restored) ~and everything inbetween~
Reply:Originally Posted by dieselcowboy460Certainly not overkill! Looks awesome! How about some LED's in it?
Reply:It looks good but for tie down points I have found that 1/2 inch chain links from chain removed from service works well and will except the S hooks from bungee cords to 1 inch ratchet straps or ropeLast edited by Stephen Dyck; 03-03-2014 at 03:57 PM.
Reply:Good Idea Stephen I probably should add a couple more tiedown points on each side.If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Made a removable rear section that drops down into the rear stake pockets and bolts onto the bed with 4 - 3/8" bolts.Seems to work well.  If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Looks really good!
Reply:Originally Posted by Bostick101MOAR LIGHTS!!!!
Reply:Yeah, that is WAY too pretty for me to use. Amazing work. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Nice, the cool thing with the long bed rail sides is that you can always weld on additional racks if needed. Nice job.