Truck rack over a bed cap/cover

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Wow, I had difficulty just naming this thread...is it confusing enough?It is a potential project I may tackle this weekend, but I could use some advice. I have a 2001 Toyota Tundra Limited Access Cab, with a Snugtop Truck Bed Cap/Cover. Snapped a couple photos below. My bed is only 7' so carrying long stock is challenging. Considered doing a hitch mounted bed extender but that makes me awfully long. I'd love to add a roof rack of sorts but they will run well over $200 and don't really seem to be very compatible with my cab. I don't love the cab, and have considered losing it and building myself a headache rack with and add-on rear rack, and complete it with a tonneau and some tool boxes, so maybe that in the future. But for now, I am considering trying to build a rack around my cab. Does the basic design drawn in sketchup below look feasible? It depicts, of course, one of four identical supports, and I would add both cross supports and lengthwise supports on top. The angle would be sandwiched between my bed rails and the cab. I envision using some rubber mat to actually have the top of the rack slightly braced against the top of my cab (to prevent movement), with the majority of the weight supported by the rails. May also need some rubber in between the lowest portion of 1" tube and the bottom of my cab to prevent any rubbing or paint damage. Thoughts? Do I have enough angle on my cab to make it fit (I know you probably won't be able to answer this, I need to do some measuring and mock-up)? Will the sandwiched angle iron support the load? Should I consider other materials than 1" square tube, 1/8" thick and 2" angle 1/8" thick? Attached Images
Reply:The ones I've seen done, the angle faces down and "clips" over the rail preventing the rack form sliding to the outside. The "flat" on top extends past the cap and the legs come down onto that. Because the legs are supported off the edge of the truck on the upper portion of the angle, the angle needs to be fairly stout,.No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:My first thought was when you said get rid of the cab.  Kinda makes it hard to drive as the cab is what you sit in.  However it's understood.  Generally called a topper or cap something along those lines.I would not do a small section of angle.  You place a big load in a small area.  I don't see a reason you can't do this, but I believe you should use a piece of angle iorn the full length of the bed.  This will help spread the load.  While a full lenght probably will not be needed it will also give the cap something to seal against the full length of the bed.  The second problem I potentially see is the angle will not make it far enough away from the cap for you to put the square tube between the angle and cap.  If so I would imagine it would stickout quite a bit.I would start with a vertical piece welded to the angle iron.  My thought is to make it tall enought to cut half the angle needed.  With the second piece cut at half the angle they will match up correctly with no gaps.The biggest thing would be how much weight are you going to put on it.  built.
Reply:Originally Posted by DSWThe ones I've seen done, the angle faces down and "clips" over the rail preventing the rack form sliding to the outside. The "flat" on top extends past the cap and the legs come down onto that. Because the legs are supported off the edge of the truck on the upper portion of the angle, the angle needs to be fairly stout,
Reply:Originally Posted by kcb37My first thought was when you said get rid of the cab.  Kinda makes it hard to drive as the cab is what you sit in.  However it's understood.  Generally called a topper or cap something along those lines.
Reply:Instead of using angle, can you use plate instead? Should give you more options with an outrigger type of mount.Lincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.
Reply:Originally Posted by WyoRoyInstead of using angle, can you use plate instead? Should give you more options with an outrigger type of mount.
Reply:Next time use a tried and true designing aid...Google Image Search. I typed in 'rack over pickup cover' and there were many other 'hits', but that one showed the clearest picture.Lincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.
Reply:Originally Posted by WyoRoyNext time use a tried and true designing aid...Google Image Search. I typed in 'rack over pickup cover' and there were many other 'hits', but that one showed the clearest picture.
Reply:Maybe I can help with the question you had for DSW.  Instead of the angle horizontal on the bed with the vertical piece pointed up outside of the cap it would be horizontal on the bed with the vertical piece pointed down inside the bed.  (believe you understand that, if I understand correctly this is what he was saying)  The "flat" on top extends past the cap and the legs come down..." The flat being the horizontal piece of the angle, or the side of the angle bolted to the bed rail.  That horizontal piece would be very wide so it would stickout past the cap and bed.Much like the aftermarket rack shown, the angle would at that point be the flat plate the tube is welded to.  So you would have some very "offset" angle one side could be 2" the other I would imagine around 5" to cover the bedrail and stickout.I understand your concern with my though and the torsional load or the weight trying to twist the angle and rip the legs off.  Had not thought of that, but make sense and kinda think DSW has a good idea to help with that.How much weight totally get that.  I dont' buy alot of metal myself try to use what I can find for free and then buy a little here and their when I have money.  But for what I haul the load/weight varries alot.  Depending on what you think of and want to build.  Materials and weight can change drastically.  Knowing a limit is what is important, so you can overbuild atleast a little and have that safety net.Hopefully that make some sense.
Reply:Originally Posted by kcb37Maybe I can help with the question you had for DSW.  Instead of the angle horizontal on the bed with the vertical piece pointed up outside of the cap it would be horizontal on the bed with the vertical piece pointed down inside the bed.  (believe you understand that, if I understand correctly this is what he was saying)  The "flat" on top extends past the cap and the legs come down..." The flat being the horizontal piece of the angle, or the side of the angle bolted to the bed rail.  That horizontal piece would be very wide so it would stickout past the cap and bed.Much like the aftermarket rack shown, the angle would at that point be the flat plate the tube is welded to.  So you would have some very "offset" angle one side could be 2" the other I would imagine around 5" to cover the bedrail and stickout.I understand your concern with my though and the torsional load or the weight trying to twist the angle and rip the legs off.  Had not thought of that, but make sense and kinda think DSW has a good idea to help with that.How much weight totally get that.  I dont' buy alot of metal myself try to use what I can find for free and then buy a little here and their when I have money.  But for what I haul the load/weight varries alot.  Depending on what you think of and want to build.  Materials and weight can change drastically.  Knowing a limit is what is important, so you can overbuild atleast a little and have that safety net.Hopefully that make some sense.
Reply:Found with "topper racks" Google Image searchMillermatic 200Hobart Handler 120Victor O/A & Ramco BandsawLincoln 225 ACSnapOn AD HoodMiller XMT304/22AHypertherm Powermax 1650 G3Lincoln Idealarc DC600 w/Extreme 12 VSMiller Digital Elite "Joker"