Pick-Up -- Plastic Pallet Holder (Help Needed)

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Hey Guys,Thought I'd ask for some insight here. My next door neighbor asked me to build him this metal frame to support plastic pallets. The pallets can have up to 2000lb each of weight in there, now he's only going to have a maximum of 2 on there at a time. Here's what the palllets kinda looks like:My initial thought was to have all the weight resting on the top side rails. Would those rails be strong enough to support that? If not, what would be the best thing to do on the underside to make it work properly? I don't normally deal with projects like these, so any insight on how to mount it would great. I also have no real idea on how to use the mounting on the top of the rails. The main tubing used is 2" square tubing 1/8" wall spaced 12" apart. The angle used is 1.5" - 1/8" thick. And the sheet metal is a 16GA. The tubing underneath the square tubing just runs straigh across without any perpendicular tubing going through the center or anything. Lastly, since I don't have a table big enough to mount the whole thing, I had to stack it up and use a level to do it with, but the level is only so long, so now 2 of the corners bow up a bit as noted in the one pictures. I thought that when I welded the angle, and had 2 guys step on those corners, that it would of cured it. Its alot better than what it was, but would still like to try and straighten it a bit more, what could I do to help with that? Attached Images
Reply:I'm a bit confused. Are you building a rack to double stack pallets for storage, or so you can span the side walls of the pickup with 2 singles?If you are spanning the side walls, 2" tube isn't strong enough, and I seriously doubt the side walls of the truck will take 2 ton going down the road like that well. I think the shortest pallet rails I ever worked with were 3" tall 11 ga. and the "heavy" ones were 6", and the "super heavy" ones 8"..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:Originally Posted by DSWI'm a bit confused. Are you building a rack to double stack pallets for storage, or so you can span the side walls of the pickup with 2 singles?If you are spanning the side walls, 2" tube isn't strong enough, and I seriously doubt the side walls of the truck will take 2 ton going down the road like that well. I think the shortest pallet rails I ever worked with were 3" tall 11 ga. and the "heavy" ones were 6", and the "super heavy" ones 8".
Reply:Originally Posted by chimmikeI agree with this. What is the non-trailer load rating of the bed of the truck?
Reply:Thanks for the feedback guys.Yes that is suppose to extend from one side to the other, to have a maximum of 2 pallets going side by side.What would I need to make this better? If I put a another 2 pieces going the other way underneath the tubing of the sheet metal (so they're spread 4' apart going lengthwise of the truck), and then make a box underneath it to lift it up from the rails a bit and use the floor to put the weight on that? Thanks in advance.
Reply:I don't know about you, but I wouldn't want to be driving around with 2 tons up higher than the bed rails.  I don't care what kind of truck it is.Best solution is to ditch the fuel tank, drop the tailgate, and slide them in end to end.Second best (if he wants to haul in the truck) is a flat bed instead of the box.Third choice (what I personally would do) is to use a trailer.Not what you were wanting to hear, but that's my 2 cents.My name's not Jim....
Reply:Originally Posted by BoostinjdmI don't know about you, but I wouldn't want to be driving around with 2 tons up higher than the bed rails.  I don't care what kind of truck it is.Best solution is to ditch the fuel tank, drop the tailgate, and slide them in end to end.Second best (if he wants to haul in the truck) is a flat bed instead of the box.Third choice (what I personally would do) is to use a trailer.Not what you were wanting to hear, but that's my 2 cents.
Reply:I agree with Boost, what you're making really isn't a good answer to his needs.  He can leave the tailgate down and still get 2 pallets in the bed if its a longbed, he'd just have to secure the rear container real well, and he could still stow his gear on the sides of the containers.  A flatbed would be a much better/safer solution.  I have no idea of your operating costs, or cost of material in your area, but it looks like you've got a decently equipped shop; why not build him a flatbed yourself??  Like i said, I have no concept of your operating expenses, but buying all new material I can build, and install a decent bed for less than half of his $7,000 quote.....
Reply:Is this rack going on longways or crossways?  I am confused...   I really don't think in any way would I want to be a part of putting it on crossways hanging out past the bedsides.  Longways I think has more promise.  I bet you that truck is overweight with 2 ton in the back, depending how ford rated the chassis.  Either way you have to go down and tie it to the frame and crossways is just going to be tough I think to tie into the frame as good and more unstable.
Reply:Originally Posted by LightsPayload on a F350 Dually is ~ 3 tons... Somewhere between 5-6,000.
Reply:Originally Posted by DSWTrue, but that's probably not figured on loading the bed walls. 5-6K is figured spread out over the floor of the bed.  You are adding quite a bit of lever arm to the weight by applying it all on the outside edge of the bed. the sheet metal walls to floor connection was never designed to take that sort of load.I have to agree with Boost, that's a lot of weight high up above the center of gravity on that truck. Handling will definitely suffer big time.
Reply:Originally Posted by DSWTrue, but that's probably not figured on loading the bed walls. 5-6K is figured spread out over the floor of the bed.  You are adding quite a bit of lever arm to the weight by applying it all on the outside edge of the bed. the sheet metal walls to floor connection was never designed to take that sort of load.I have to agree with Boost, that's a lot of weight high up above the center of gravity on that truck. Handling will definitely suffer big time.
Reply:So I've certainly scrapped the idea of putting all the load on the walls. I've been doing some calculations, and some 3D mocking on solidworks and I think I might have a better supported idea with all the help from you you guys. I'll post up the 3D renderings in a few minutes. But essentially what I've done is added 2 more tubing on the underside of that part that run lengthwise (2 more pieces that are 2" square 1/8" wall), and the whole thing is then mounted on 4 legs that are 3" square 3/16" wall, that sit on square platform.
Reply:I put 8,500 lbs in the bed of my 2000 F-350 dually once.   wasn't that bad really.    You knew you had weight back there and you definately needed to mind your driving and the road conditions.     But to put that much weight above the bed rails is pretty damn crazy.   Combine that with the weight of the fuel tank your asking for a disaster.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Well here's where I'm at right now with it. Let me know your thoughts! Attached Images
Reply:The bed of the truck will easily handle 2 tons.  I regularly tow a gooseneck with around 4500-5000lbs drive axle weight, and I'm barely on the overloads.  This is on a 94 F-350 11,000gvw.To save weight lose some of the crossmembers, and replace them with fewer heavier wall crossmembers, or dimensionally thicker crossmembers.  A pallet is spread out weight, not concentrated weight.Your fore and aft runners under the pallet should be heavy, or at least dimensionally thicker.  Dimensionally thicker with lighter wall would be ideal.  You can also spread the weight out with another middle runner in contact with the floor of the bed instead of the two you've drawn.Subsititute, just as an example, 2x2 tubing with 2x4 tubing in a lighter ga.  I would imagine the higher platform will be easier to work with on most loading docks instead of having to ground load the pallets into the bed.  The pallets can be set on the platform, then pushed ahead."Any day above ground is a good day"http://www.farmersamm.com/
Reply:I just looked again.  YOU'VE ALREADY GOT THE PLATFORM BUILT Redesign the supports underneath.  3 runners across the width of the bed on the floor of the bed to spread the weight out.  That's only a load of 700lbs per runner, pretty light actually."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by farmersamm  I just looked again.  YOU'VE ALREADY GOT THE PLATFORM BUILT Redesign the supports underneath.  3 runners across the width of the bed on the floor of the bed to spread the weight out.  That's only a load of 700lbs per runner, pretty light actually.
Reply:Most of the time he will only have 1 on there, but 2 when he really needs to.
Reply:Originally Posted by farmersammThe bed of the truck will easily handle 2 tons.  I regularly tow a gooseneck with around 4500-5000lbs drive axle weight, and I'm barely on the overloads.  This is on a 94 F-350 11,000gvw.To save weight lose some of the crossmembers, and replace them with fewer heavier wall crossmembers, or dimensionally thicker crossmembers.  A pallet is spread out weight, not concentrated weight.Your fore and aft runners under the pallet should be heavy, or at least dimensionally thicker.  Dimensionally thicker with lighter wall would be ideal.  You can also spread the weight out with another middle runner in contact with the floor of the bed instead of the two you've drawn.Subsititute, just as an example, 2x2 tubing with 2x4 tubing in a lighter ga.  I would imagine the higher platform will be easier to work with on most loading docks instead of having to ground load the pallets into the bed.  The pallets can be set on the platform, then pushed ahead.
Reply:Easy solution, take out the fuel tank and load the pallets.I have a 1990 f-350 crew cab dually, weight is 74?? empty(at least that what the scrap yard scale says).  My neighbor burns wood pellets. When I pick them up for him, the pallets are stacked about a foot higher then my cab. The weight is not an issue for the truck but I think if they were up on a platform it may get top heavy.If he hauls more then 2 at a time, Might consider investing in a trailer. just my opinion.
Reply:Originally Posted by dswsamm you're thinking one pallet. He's talking 2, so the loads would be a bit heavier, but not extreme with 3 runners.
Reply:Well here's where I'm at with it today. Attached Images
Reply:Well finally finished this project!  ... now where's that cold beer!Here's what it looks like on the truck all mounted. Attached Images
Reply:The issue here is not the platform that you built, its plenty strong enough. You have done what he asked of you but this is a recipe for bad things. This guy should have his head checked. Its reasons like this that they build large flat bed trucks that are designed to be freighted. Nice job on the build though.I agree. Looks great. You did a nice job, but I would not want my name attached to it. I know curves on the freeway I would not dare take that truck across. The I10 to i17 stack in Phoenix is about 100ftin the air, and that top heavy going arround that curve at 65 would surely find the quickest way to the ground after going through the barrier.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Looks good for what it is...What are the little cuts of angle iron at some of the 90's??  why not gusset it??I think the ratchets will lead to the bed getting beat up.
Reply:Originally Posted by bottlefed89Looks good for what it is...What are the little cuts of angle iron at some of the 90's??  why not gusset it??I think the ratchets will lead to the bed getting beat up.
Reply:Long as you're careful driving it, it ought to be ok.I load 4 5x6 round bales on my flatbed, and it handles ok.  Be about the same height as this.  Weight would be close too.....around 5600lbs."Any day above ground is a good day"http://www.farmersamm.com/
Reply:dang sam you must roll a tight bale.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.