Side rails, headache rack, and a tool box lift for my truck

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Just wanted to share my latest project. I bought a new truck and being the just in case minded guy I am I decided to make side rails, a headache rack, and suspend my tool box of the bed on my truck. Im working on the tool box part now, but figured Id share the photos I do have.Apparently all the metal shops are busy so I had to bend my plate by hand.... Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Im finishing up the rack and then going to work on my tool box lift. But here are some pictures of current progress... Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Looks good. Paint or powder coat?
Reply:Cause of cost and wait time, Ill probably just paint it myself. High gloss black.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Easier to touch up too
Reply:Very nice! How did you mount it to the top of the bed.  I need to fab up somthing for my dad. He can't really get up  in the truck anymore but carries heavy stuff with only 2 straps.
Reply:Right now its just sitting on top of the rails. My plan is to drill holes and bolt it down. Theres enough of a lip to pop a hole and run a nut and bolt through it.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:How did you bend it?Miller BobcatHarris cutting outfitMiller spectrum 625 plasmaVariety of shopmade tools
Reply:Its a long painful process but Ill tell you the way I should have done it versus what I actually did. What I did since I used diamond plate, I cut the flat side 2/3 of the way though with a cutting wheel. Leaving the diamonds intact. Then cut every 6" into what would be the flange. And section by section bent them. Then I clamped the piece to a heavy I beam here at the shop and re-welded the cuts and polished them off. The way I actually did it was a lot harder.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Just an update: Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Looks great, are you going to paint that box?
Reply:I just just painted it a little while ago. Tomorrow I should have the whole thing done. Pics to follow1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Another update Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:And done! Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Very nice work.
Reply:Wow! Great job on that! You must be proud.PlasmaCam CNC cutterLathe and Band SawClamps
Reply:It came out nicer than I anticipated. I may have over done it a tad but o well haha1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Great job! It looks fantastic.
Reply:Nice work..... siderails, headache rack and tool box all look like they are suppose to be part of the truck.. almost factory looking. Qualified & experienced at welding scrap metal
Reply:I'm impressed! I've been wanting to throw a JobBox in my truck for some more secure storage, but didn't like how they sit 6" off the ground with their feet. I had toye with the idea of suspending it halfway up the bed, so I could have a foot or a bit more under the box to throw smaller things in there.. but couldn't quite imagine what it would look like in my head..It looks amazing! If I may ask, what size box is that? The largest I've seen stocked locally at HD/Lowes is around 4 feet by 2 feet wide.. a little too small for my truck.How did you make the rail covers? Did you cut on the traced line then use thin stock and just copy the cut's curve with some creative tacking? Either way, it looks great! Thanks for sharing!Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:Thanks for all the likes guys! JohnR to answer your question; my tool box is 48-1/4" long by 24-1/4" wide (exact dimensions). I know Home depot has a larger selection of Ridgid tool boxes, which basically your buying a Knack tool box because knack makes the tool boxes for Ridgid. I know they carry a few sizes bigger. To get the clearance you want underneath the box just do what I did to my box... whack the feet off. If you still want a bigger box, I would look for a Knack dealer and look at their inventory. For my rail covers; what I did on that line I traced out, I followed the curve and cut the "flange" to make individual sections. Kinda like breaking the steel along the curve. I took a cut off wheel and cut about 2/3 of the way through and then bent it. The shorter you make those sections the easier it is to bend, well in my case because I used 3/16 diamond plate.... I ordered 10 gauge but received 3/16 for my money. I wasn't gonna argue haha. It takes some messing around with but if there's not metal break to be found it works out ok1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:*Golf Clap*Nice truck too, BTW [Account Abandoned 8/8/16 Please Do Not Attempt Contact Or Expect A Reply]. See you on YouTube! -ChuckE2009
Reply:Ok. I'm at it again with my truck. I finally decided to make some side steps for it. It's based off what ranch hand makes for my truck except with my own touch to it.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:This what ranch hand offers. I'm basing it off the same design just different.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Started off with a piece of 2-1/2" sch 40 pipe. Since it's going to be over 8'long. To remove weight I cut it in half down the length of it. Then I'm going to weld a " back" or " web"  to it out of 14 gauge sheet metal to strengthen it and at the same time not add too much weight. Should have it welded out pretty quick. Then I'll start working on the steps.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIGhow did you cut that piece of pipe in half like that? What tool did you use?Miller TrailBlazer 301Miller 12rc feederMiller ShopmasterMiller 22a feederPlasmaCam CNC TableHypertherm 45 cutterDrills, saws, blast cabinets etc.
Reply:whiskeyrichard I used a grinder with a cut off wheel. Killed 6 blades total.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Well you did a great job splitting thatcan't wait to see the restBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Nice job !  That's a longgggggggggggggggggggggg cut, splitting 8' of 2 1/2'' in half. Looking forward to the finish project.
Reply:Just an update for y'all. I've built my actual step rungs. Going with 1-1/4"  sch 40 pipe. I don't have a pipe bender so I just welded in a 45. Grinded the weld smooth. I went big on my steps I may have to make the bed step narrower or not put it on entirely. I did a little mock up to get my thoughts in line. And tomorrow I'm going to attack it again Attached Images1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Very nice work man.  I am wandering how you find the right place on the pipe to cut it in half, if that makes sense?
Reply:I secured the pipe on my tripod and used a pipe center finder or curve o mark I think it's called. And I marked the " horizontal" plane of the pipe. Then with a 3 foot level I connected the dots. Then chased the line with a cut of wheel.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:After a bit of trial and error I was finally able to mock bolt it to the truck. Still far from done. Still locating and building the braces that are going to the frame.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Originally Posted by jesse302bossRight now its just sitting on top of the rails. My plan is to drill holes and bolt it down. Theres enough of a lip to pop a hole and run a nut and bolt through it.
Reply:Just an update1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Looks very good. Only a few small problems, you used the wrong size bed as a pattern, I have an 8 foot bed.Mike
Reply:I love how everytime you get in your truck youll be stepping on f150. Makes me warm inside haha love my chevys. Great work btw has def given me something to gather ideas from.....Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Originally Posted by leightrepairsLooks very good. Only a few small problems, you used the wrong size bed as a pattern, I have an 8 foot bed.Mike
Reply:I had a rigid job box, but I didn't like how it leaked water from the lock openings.  Didn't matter when I was able to keep it under storage or in the shop, but I went to a greenlee box for my weather proof box.Great job on the truck.  Looks real sharp!
Reply:[QUOTE=chevydyl;3461991]I love how everytime you get in your truck youll be stepping on f150. Makes me warm inside haha love my chevys.Hey, I like that !!!!!     That's better then what this guy did to his Ford !     http://weldingweb.com/vbb/showthread.php...y-FOB-Big-Bang!
Reply:hahaha there's always one in every forum.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Hah had to poke a little fun...my yard truck/plow truck is a dodge that I trash on really dont care if I break it but it hasnt yet. I call it a yard truck cause it doesnt leave my road. Did that once and had to tow it home with a ford ranger hahaha. But its been running great since that incident dont know what caused it. Swapped out a chevy coil and it fired right up. So I put the dodge coil back in and its been running since.....i dont have a calvin pissin on ford sticker...im not that racist but I would never buy a ford but like the dodge if it was given to me id def use it....how are you gonna cut the f150 logo out?Last edited by chevydyl; 12-25-2013 at 02:39 PM.Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Well instead I cut out the Chevy logo for the driver side and GMC for the passenger side. Thanks for pointing that out earlier. Hahaha I'm just kidding. I thought about cutting the logo into the plate, but decided not to due to the fact the plasma cutter I have won't cut 1/8" . I'm kicking around the idea of cutting the letters out of 14 gauge and laying them on top. Or sticking them to the side of the pipe so they'll be better seen. My plate is full right now building the passenger side. Figure I'd wait till both sides are done and primered. Maybe by then I'll know what I want to do.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Hahaha that was a good one!!! Got a laugh outta me...what you mean it wont cut 1/8i ???? I waz thinkin the same about cutti g it outta the plate but it might bend the skinny parts when you step on it. I like the idea of the letters being on top...maybe drill some holes through the step and plug weld them from the backside for a better finished look.....you could go as far as using stainless for them and then polishing them to a bright luster....man that would look good black..or just weld studs on the letters and bolt em to the plat3 and powder coat them silver.....Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Its a small portable plasma cutter.It'll only cut up to 1/8" . Barely at that. It's a small self contained unit. We bought it for a stainless job we did. And that actually sounds like a solid idea. I have some stainless lying around. 14 gauge I think. Hmmmmm..... it would look nice with the black background of the step. 1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Hells yeahs and it would match the f150 chrome logo on the fender thats laid on black...which pretty much anything chrome or silver is pretty hot on blackMiller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:Just another update. Finally knocked out the passenger side and started painting. 1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Finally finished. Took me a while to post it.1982 Lincoln SA 2001980 Lincoln SA 2501996 Lincoln SA 2501994 Lincoln Ranger 82005 Lincoln Eagle 10,000Millermatic 211 MIG
Reply:Nice....but you aint finished yet where are the logos????Miller Syncrowave 210 w/CK FlexLoc 150  3/6/14ESAB PCM 1125 Plasma CutterAtlas 12x36 LatheACER 9x42 3hp millHarig 612 Surface GrinderDRINK Machine              welding&fabrication
Reply:I'm debating whether or not to put them on. I'm afraid I might cheapen the look of the truck. And also my regular hub kicked in again. Haven't had the time to stop and plan it out much