Truck Headache Rack

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Got most of the work done on the headache rack I'm making for my Chevy Colorado.Has 2x3'' angle for rails, 2'' sq for the uprights, some 1x2'' rect for the lower bar and two center uprights, then some 2x6 across the top.Gussets are diamond plate, caps for the outer uprights are diamond plate, and where the cutout is for the 3rd brake light is filled with diamond plate. Did this to match the diamond plate on the bumper I built last year. The welds aren't the prettiest, but for a light duty truck, they will work just fine. At most, I'll have a ladder or some lumber or metal racked up.Just need to find some 3/8'' thick x 3'' diameter rings to put on the inner rails for tie down points.sorry, pics are a little large.Last edited by 06colorado; 10-02-2011 at 11:27 AM.
Reply:Post somepictures when you are finished. It looks good so far. You will be surprised how much the paint will hide some minor imperfections. Again WELL DONE.Miller BobcatHarris cutting outfitMiller spectrum 625 plasmaVariety of shopmade tools
Reply:Great build. Keep us updated.We are on our way to being farmers! Our site is always under construction so check back often for updates.  http://www.philosophyfarmstyle.com/
Reply:Looks great are you planing on get some LED brake ligths for those holes?i want to see some pics of the final product
Reply:Yes, led brake and led reverse to match my bumper.this pic shows when we set the upright on the rails at the shop. also has the bumper in it that i did last year. thread for bumper.  still need to make a filler plate or get some rubber to hide the gap between the bumper and bed from the body lift.http://weldingweb.com/vbb/showthread.php?t=36074i plan to sandblast the bumper, the rustoleum didn't last long and is faded real bad. going to do an automotive satin black from summitracing on the bumper and rack so they'll match. after that is all done, i might make some nerf bars of some sort or just some small steps, i dont quite know yet, maybe nothing at all.
Reply:Looks good, should really stand out once it is painted and the lights are in.  Be sure to post some pics.Aren't you glad you didn't just buy one ot those clone backrack's from the local auto store that you see on every second p/u truck.Post some pics of your bumper, looks like a nice job also."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:you wont have any one rear-ending you with all those break lights, I like it "Those who hammer their guns into plows will plow for those who do not."Thomas Jefferson."When the people fear their government, there is tyranny when the government fears the people, there is liberty."Thomas Jefferson.
Reply:Got the rack on the truck. Just needs the lights wired up. Truck is rather dirty, oops.Going to get a trailer wire junction box, run my wires into there, then run a set to the bumper and a set to the rack. Oh, and the lights on the rack match the ones on the bumper. I know its probably not best for the gussets to be bent like that, but its more for looks. Some rather thick material all around. In a couple months I'll sandblast it real good and do a better paint job. This is just a $10 rustoleum in a can roll on job so I can get it outa the garage.Last edited by 06colorado; 01-23-2012 at 10:13 PM.
Reply:here is the bumper pic.the side and the angled part are wrapped with diamond plate, then the top is diamond plate and the step also.used some 1/2'' x 6'' plate for the mounts, 2 bolts in the sides, 2 thru the bottom. gussets on either side where the plate mounts to the bumper, and that tie the step/hitch to the plates too.
Reply:I can appreciate the desire for big ol heavy duty stuff, but 1/2" may be a bit of overkill for your 3/16" frameExperience is something you get right after you need it
Reply:Yea, probably was overkill. It was what we had left at work from a 20ft joint and didn't have any6'' x 3/8'' or 1/4''. Think I got it free, so figured why notLast edited by 06colorado; 01-23-2012 at 10:51 PM.
Reply:Nice work getting the set together.  I like the low profile nature of the rack.  It isn't sticking out from the cab all over the place.  When I see racks like that I think ill fitting and dragging in the wind.  Anyway, nice style.Will you be adding in any expanded metal on the sides (I see you've got a rear slider).  Without the toolbox I've had stuff too close for comfort on the windows.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:Great Job!!! makes that Colorado Stick Out!!! Keep up the Quality Work!!Lincoln 305GUnion Carbide TorchDon't Worry About the Mule~Load the Wagon!
Reply:Thanks for the compliments.As for the expanded, I'm really not sure. I've got 2ft x 10ft of 3/4'' flat expanded left from doing the sides on my trailer, but not sure if I should just cut to fit inside the opening or cut to fit on the back side between the rack and window.That'll wait a couple months for it to warm up though.
Reply:For fit and finish I'd go inside the opening. If you just put it on the back it'll look like and afterthought that just got thrown on because you had metal left over and could.Personally I'd get her cut to fit, then use some 1/2" or 3/4" angle to frame it out. it'll add a little strength to the expanded metal and hide all the cut ends. I'd do it both in front and behind the expanded metal just for the finished look.I'd like to see more pictures of that homemade tow set up.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:I prefer flat bars welded in at an angle to sort of make louvers to exp. metal. If you go with the exp. metal definitely center it in the opening.Nice looking.Leo
Reply:I'd also put the expanded metal inside.  This is how we've done all our racks.I'm not a louver person. I feel like I'm looking out of these Last edited by Monica; 01-24-2012 at 02:52 PM.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:I'll have to try the expanded with the angle or flat bar. Centered in the opening for sure with the center open. I'm not much on louvers. The flatbeds we have at work all have the louvers on the uprights and makes it a lil harder to see when changing lanes or backing into buildings.
Reply:looks good, turned out really nice.i especially like the rear bumper. nice clean installation. works well..
Reply:got wired up todayvid of lights.skip to 20 seconds in, i dont have a movie editor yet on my laptop[ame]http://www.youtube.com/watch?v=Aeq-MIihDsU&context=C343be7eADOEgsToPDskLQe422pzTnmYEN  X0Fi2d7q[/ame]so far, it's done for now.
Reply:^^ saweet!!Some Blue , Some Red & Some GreyProverbs 16:2-3.2 "All a person’s ways seem pure to them, but motives are weighed by the Lord. 3 Commit to the Lord whatever you do, and he will establish your plans."
Reply:Looks real good 06Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand