Headache Rack/Cab Guard

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Been building this per the customers wants/needs for a Chevy 3/4 Ton...Will take STT lights, backup/work lights and a brake light in the center. Picture below that is my current headache rack.
Reply:looks real nice. how did you cut those holes......they look real clean from these pics.Miller TrailBlazer 301Miller 12rc feederMiller ShopmasterMiller 22a feederPlasmaCam CNC TableHypertherm 45 cutterDrills, saws, blast cabinets etc.
Reply:Originally Posted by whiskeyrichardlooks real nice. how did you cut those holes......they look real clean from these pics.
Reply:Originally Posted by TSCGG13Cut the two radii with a hole saw, then used a metal blade in a jigsaw to cut the flats. I used to use a grinder and a zip disk, these are much cleaner with less clean up.Thanks!
Reply:You definitely know chit from Shinola.
Reply:Nice work, I've been debating if I want to build a headache rack and bed rails for my truck or find a flatbed.  Definitely nice to have those lights up there if you have a trailer that the lights go out on the road.
Reply:Originally Posted by walkerweldYou definitely know chit from Shinola.
Reply:that is one nice looking guard. looks more better than factory built!i.u.o.e. # 15queens, ny and sunny fla
Reply:Originally Posted by TSCGG13Thanks! I sure try. I have another one to build going on a service truck also.yep I love mine. My orange lights strobe when we're moving equipment. This customer wanted reverse\work lights.The service body headache rack I have to build is a light bar basically I have to make strobe and also make work light mounts.thanks guys, I love building these things. Also, on every one I make I install a light plug on the bottom so they are easy to remove for painting or if the truck is sold.
Reply:Good lord, that's a ton of lights. Good job!
Reply:I see no gussets or support for the rack.  What keeps it from folding into the cab?Lincoln mig-Pak 180, Leather gloves, vice grips, a couple screw drivers, needle nose pliers, a file, dog, cat and a bird
Reply:Originally Posted by pxtysonI see no gussets or support for the rack.  What keeps it from folding into the cab?
Reply:Great job, like said above, nicer than factory!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:That came out really good
Reply:Originally Posted by Murphy's lawThat came out really good
Reply:Here's the rack going on the service bed. It's going on a C4500 Chevy.It will have strobes on the front and rear of the top bar, as well as work lights front and rear.Sitting on the saw horses for paint right now.
Reply:Real nice work man
Reply:Thanks! I have more pictures of the one I just completed but it will have to wait until I get to a computer.