Headache Rack Project

admin

Well not quite completed but started working on a Heavy Duty headache rack for my Super Duty . I went to a local truck accessory dealer to get  a front and rear Ranchhand Style bumper ordered since the good ole insurance is paying for the bill. While there I was quoted $550 installed for a basic heavy duty headache rack. So after about $150 in material and a day of work off and on i got most of it complete. Also it has bed rail which will have some tubing added to the top of it. Also i have welded brackets for some flood lights to light up the welding trailer or work area at night. Still need to add the top rail tubes to the  bed rails, clean it up prime and paint it. Another 1/2 day should be done maybe a couple hours if I can stay on task and not get bothered  Bonus kids out of school for the summer (FREE LABOR lol )EquipmentLincoln 200SATrailBlazer 275MillerMatic 252Hypertherm Powermax 600
Reply:That is a very nice fit, looks great! City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:I made it from 1 1/2"x3" rect tubing the bed rail cap is 1/4x4" Flat the top rails will be 1 1/2" swuare 1/8" wall so should hold up wellEquipmentLincoln 200SATrailBlazer 275MillerMatic 252Hypertherm Powermax 600
Reply:Looks good, I like the rectangular tube you chose, looks beefy.
Reply:I like your work gunlocator and I was wondering if you could share with us where you got your lead reel kits from,an address or E mail would be much appreciated,again the headache rack is alright and do want to see it after it's painted. Thankyou LynchWood.
Reply:Headache Rack back from powdercoat sorry for the crappy pics it was getting dark As for a email for the reels I cannot seem to find it its Kentex Fabrication He does kits on fleebay You have to do all the work assembling and welding together he cnc cust the side plates and cuts the material to size and resses in the bearings and thats it. Your looking at 4-6 hours to assemble properly but well worth the satisfaction of building the reels.EquipmentLincoln 200SATrailBlazer 275MillerMatic 252Hypertherm Powermax 600
Reply:Very nice looking rig, need to get building one for my GMC, always nice to have when moving wood and carrying things that might end up in the window.  I like the square tubing and the design.Trbo
Reply:I used square on the top rails and rectangular on the headache rack it self its pretty stoutEquipmentLincoln 200SATrailBlazer 275MillerMatic 252Hypertherm Powermax 600
Reply:The only minor issue I have is that it's welded to flat stock. Personally I would have used angle iron with the leg turned down into the bed for stiffness. I've seen several done your way and the rack can hit the cab it something gets tossed hard against the rack in a sudden stop as the flat stock flexes. I thought perhaps you were going to stiffen it with the side rails instead, but it looks like you stoped them short for the tool box to sit down on the flat.Don't take offence at that 1st statement. Most of that sort of stuff I build needs to take a real beating on work trucks. Other than that looks like a good job and very well made.
Reply:With the tool box bolted down there no flex noticable I tested it alsoi there is a tab under the headache rack and under the tool box area the tap under the tool box to the headache rack area you cannot se forms a 90 and runs 16" Very very ridgidEquipmentLincoln 200SATrailBlazer 275MillerMatic 252Hypertherm Powermax 600
Reply:Hey.  Hate to bring back a dead thread but how much did you angle the 2 outside rails in to match the cab?
Reply:yea thats what i was just wondering. On the base what was the angle you cut on the rect tubing on the vert sides of the rack
Reply:Seems to me the easiest way to find the angle for any cab would be to clamp some stock in place to match the cab, and use a bevel to copy the angle.Different cabs have different slope on the sides."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Then ya gotta smoogie(highly technical term) the joint to make it look right.The further your get offa vertical, the more you have to massage the joint to make it look perfect."Any day above ground is a good day"http://www.farmersamm.com/
Reply:IE, the cut has to be perfect"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by farmersammSeems to me the easiest way to find the angle for any cab would be to clamp some stock in place to match the cab, and use a bevel to copy the angle.Different cabs have different slope on the sides.
Reply:guess that makes sense..never thought of that..thanks farmer
Reply:RIght i know how to find it i was just tryin to skip a step. I just had a guy with the same truck stop by wanting a headach rack with light bar rack tool box and full runners along the rails w/ tubing. . . . . . Just when i thought i had the weekend off.