Tacoma Headache Rack Build

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Decided to build a rack for my 2012 Tacoma.2.5'' sq tubing for upright3''x4'' angle for rails (maybe overkill, but had it from doing another rack)caps and Texas gussets cut by Relentless Fabalso going to use some 9/16'' t-slot nuts to mount the rails to the Toyota tail systemStill deciding whether or not to cover the welds w/ 7024 and smooth them out like the last one I built.Should have it done this coming weekend w/ it going to be 82*Not sure I like the rails. Would have liked them all the way, but Toyota made the bed come in a little so it couldn't be a full rail. Not sure if I should cut them down shorter or what.I'll be putting a 15'' led strip stop/turn/tail on each of the outer uprights.Probably going to add some led work lights also.sorry for big pics, will resize and fix this later.comments? critiques? suggestions? good or bad, i'd like to hear them.
Reply:Looks plenty stout. I like your gussetsSafety 3rdGump
Reply:i dont see no weld on that upright or that gusset. and i dont see how a guy that drives a tacoma can call himself a colorado..nice rack..
Reply:What is the point of these? And how much does it weigh?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:That racks looking awesome man. I have a 2009 Tacoma myself, and I decided to flip the angle I bed rails so I had could punch holes and have more tie down spots. How is it attached? I found the hardest part was finding clamps that fit the bed rail system.Quality craftsmanship in the shop or in the field...
Reply:Originally Posted by GambleWhat is the point of these? And how much does it weigh?
Reply:Originally Posted by weldbeadi dont see no weld on that upright or that gusset. and i dont see how a guy that drives a tacoma can call himself a colorado..nice rack..
Reply:That's very similar to what I build for my own trucks, though I use 11ga 2x3 tubing for the rack and have wire mesh guarding the window. I ran into the same problem as you regarding the curved bed rails. For my personal truck, I used bent plate in place of your angle, and ran it the length of the bed. Then I cut the curve in it with the plasma cutter. It didn't come out 100% perfect, but it was the first one I had done, and I don't need perfection on my own truck anyway.IW Local 580 NY, NY
Reply:Originally Posted by GambleWhat is the point of these? And how much does it weigh?
Reply:Good looking rack, strong and functional and not all pimped out.
Reply:Originally Posted by shortfuseSome guys also add a grid or expanded metal to it so sh*t doesn't come crashing thru your rear window.
Reply:Nice job! Looks good from here.Personally, I'd cut the angles on the box shorter.  You're only attaching to the sheet metal of the box and it's not going to make it that much stronger."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:Perfect!!!Nice clean lines. When I get another truck I'm coping this design.Dave ReberWadsworth Ohio
Reply:I would make the top cross bar taller if you plan on adding a removable rear rack.  as it looks now any material laid across it would flex and hit the roof when driving. (assuming u add a rear rack to carry stuff level above the cab..Extend the bed rails the full length of the bed if you can and throw some tie down points onto it.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:keep the comments coming. good to get some feedback. Originally Posted by noriteNice job! Looks good from here.Personally, I'd cut the angles on the box shorter.  You're only attaching to the sheet metal of the box and it's not going to make it that much stronger.
Reply:here is my last one from the colorado.wasn't 100% happy with it, but it served it's purpose. i messed up on the angles, so had to add a piece of 2x2 sq to the uprights and bend the gussets. looks good, but not as strong as a straight gusset.
Reply:Here's a shot of mine:The front rack bolts to the rails. (4 3/4" bolts, nuts welded to the rails), so that pops off in 5 minutes. The rear rack slides in through a sleeve on each top rail, and a pocket welded to the floor. Nothing flashy but it certainly gets it done.IW Local 580 NY, NY
Reply:colorado...I've got a '05 Tacoma 4x4 with the composite bed.  I've never known just what is underneath the composite rails along the top edge of the bed.  Is it solid metal wrapping up and around from the quarterpanels (like on regular PU's and BlueArc's) or is it some gridwork or frame?
Reply:Originally Posted by shortfusecolorado...I've got a '05 Tacoma 4x4 with the composite bed.  I've never known just what is underneath the composite rails along the top edge of the bed.  Is it solid metal wrapping up and around from the quarterpanels (like on regular PU's and BlueArc's) or is it some gridwork or frame?
Reply:Ooh ... Nice one.  _____________________________________________http://www.sawblade.com
Reply:Originally Posted by 06coloradothis pic may help. looks like the metal wraps around. somewhere i saw a pic of the bed with the outer sheet metal removed, i'll look around.
Reply:hmm trying to fix the big pics.couldn't edit the first post(or i'm blind and cant find the edit button)but here are smaller sized pics. Originally Posted by 06coloradocomments? critiques? suggestions? good or bad, i'd like to hear them.
Reply:just about finished up the headache rack.still need to do some grinding and smoothing on the caps, clean some slag, and sandblast.used my new millermatic 211. sure is a nice welder. ran on 230v w/ 75/25, 035 wire. don't recall the settings. still need a bit of practice.i'd still like to do a bar or rack at the rear for picking up material that is 10-12 ft.
Reply:just a little update.finally after sitting in the garage 6 or 7 months, i painted the rack and installed.still need to get those corner brackets cut w/ the texas logo instead of the R. i may see if my co-worker that bought a tacoma would like to buy this one because i'dlike to build another that is maybe 1'' shorter, out of 2'' instead of 2.5'' sq, and has stop/turn/tail lights as well as reverse lights to match the one on my other truck.not sure if i'd do full length rails or not since the tacoma has the track rails on it already for tie downs.next project is a front bumper for my colorado. maybe i'll get it going and done by winter.
Reply:got tired of no lights on the rack, so did some work and changed up the rack to add lights. cut the bottom of the top tube out, added 3" strap and then a piece of 2.5" sq tubing cut in 1/2 to cap the bottom.quite happy with how it turned out. not perfect, but works for me. used bondo to fill and smooth out. used a bit, but then sanded most off.under the truck i used a trailer wire junction box to add wiring. kept is nice and clean.used terminal block in the rack to keep it clean.definitely like the extra lighting.did the same to my brother's headache rack on his work truck last summer, adding tie down loops and a bar in front of the toolbox too.Great looking build
Reply:Sweet rack. I'd like to make a utility rack for my tacoma one of these days. Sent from my iPhone using TapatalkLincoln Pro Mig 180HF Stick/Tig Inverter WelderLincoln AC225s