Headache rack questions

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I've got a guy that wants me to build him a headache rack for his 01 F350.  What size material would be sufficient for that, he will be using it to carry ladders, lumber, and he also wants it louvered because sometimes he has the back of it filled with debris or rock even on landscaping jobs and doesn't want a rock crashing through the back window.  He was thinking expanded metal for the back but to hold off a rock I was thinking something a little more substantial.  Any ideas?  For the main frame I was thinking of using 2.5 x 2.5 1/8" square and 3/8 plate for where it attaches to the bedrails.  Then use a piece of 1/8" or 1/4" plate on the underside of the bedrail to sandwich it when bolted down to spread out the stress zone away from 4 mounting bolts.
Reply:2.5 Tubing is plent strong enough for the frame. Underneath I would use 3/8 plate same as the top. As for the rocks, unless you got bigger rocks in your neck of the woods expanded metal will be fine. There are a lot of different thicknesses and hole sizing of mesh. You can find something that is strong enough. Easiest way to have the strenghth and the visibilty factor. One other option is what we call here crusher mesh if you really want something tougher. It's a woven wire mesh, available in a few sizes, almost every strand needs to be tacked though, more labor intensive. Attached ImagesLatest Toys Miller 180 Mig and Elite Mask!!Wright Welder 225ACShop OutFitters 20/20 Bending SystemHypertherm 380 Plasma30 Years of Sparking (Electrical & Welding)
Reply:Most headache racks are contructed onto an angle iron frame work. That angle iron frame work then sets on the existing bed rails. Spreads the loads out over a wide area. Most beds nowadays are pretty whimpy.
Reply:Originally Posted by buggyboy_2006I've got a guy that wants me to build him a headache rack for his 01 F350.  What size material would be sufficient for that, he will be using it to carry ladders, lumber, and he also wants it louvered because sometimes he has the back of it filled with debris or rock even on landscaping jobs and doesn't want a rock crashing through the back window.  He was thinking expanded metal for the back but to hold off a rock I was thinking something a little more substantial.  Any ideas?  For the main frame I was thinking of using 2.5 x 2.5 1/8" square and 3/8 plate for where it attaches to the bedrails.  Then use a piece of 1/8" or 1/4" plate on the underside of the bedrail to sandwich it when bolted down to spread out the stress zone away from 4 mounting bolts.
Reply:If he wants it heavy duty I agree with using angle down the bed rail.  1 1/2" x 3" tubing looks real good on a headache rack.  Use a couple of vertical braces spaced evenly and some 3/16" or 1/4" x 2" flatbar for the louvers.  I've done a few like this and they look nice.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Cool ideas guys.  He will need it pretty heavy duty (you should see how many dents are in this truck, he's a heavy duty kind of guy  ) so I guess I'll give him an idea of how much the materials will be and go from there.  This is my first real sidejob welding so I'm excited.  Ill post pics as I go so you guys can see my amateur flux core welds lol.