Yet another hitch rack

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Here's another project I'm working on, this ones a hitch rack for my Tahoe for when we're camping but not truly off-roading. Anyway, it measures 61" x 31" and I built it big enough to hold 4 plastic Wal-Mart foot lockers. Since I'm building this on the cheap (got about $20 in it), I'm going to use some conduit (free) for the diagonal braces that run from the hitch tube to the corners. If I can find some more angle iron, I may triangulate it a bit more as well. I'm only looking to carry 300-350 lbs at a time but I'd rather be overbuilt than under. I'll get some more pics tomorrow but here's some for now. The first pic is when I measured, then measured again, then tacked, then measur...I'm sure you get the picture. The second pic is of the corners where I drilled through either the top or bottom (alternated each corner), and then plug welded and ground it flat. The third pic is of the bottom side which received regular welds as seen in the last pic. Last edited by 46/71 Hybrid; 06-27-2008 at 01:37 AM.
Reply:That all looks like 1" flat stock. I am not quite visualizing how you plan to stiffen it sufficiently to support any weight. If it's 1 " angle, sorry couldn't tell from the picts.Depending on the conduit you have available I could see doing a tube style ladder truss to take the weight. 1" or larger conduit would work well, 3/4" wold be  a bit small personally. The only issue with conduit besides the thin walls and need to cope all the joints, is the galvy finish. Be sure to grind all the coating off prior to welding and use a respirator if you weld a lot of it. wleding outdoors with a fan might be sufficient but zink poisoning aint fun so be careful of the fumes. To me conduit is an emergency material only, It's cheap but not worth the hassle.Where overseas are you stationed?
Reply:I didn't notice but it does look like flat stock from the pictures. In reality it's 1 x 1 x 3/16" angle. I wish I had gone either 1.5 or 2" but I think it'll work out. I agree on the ladder truss, with enough vertical supports it should keep the truss from bowing upwards and the angle from deflecting too much downwards. I wish I had something other than conduit, unfortunately choices are very limited down in Mexico unless I'm willing to buy a 19' stick of whatever material I choose. More pictures to come that show it from the other sides.
Reply:If you only need 1 or 2 pieces you can probably move them short distances by slinging them under your tahoe. I would go over the rear axle and tie it up with bailing wire in the middle. A good ratchet straps wraped around to cinch down and attached to the front and rear bumper will get you by. Or just take along the old hacksaw and wack it in half after you buy it. (cordless grinders with slitting wheels or cordless sawzalls are great for this).
Reply:Ok more pics...OverviewThese are the welds to the hitch tubeThese are the backside weldsThese are the beads I ran to keep it from rocking in the receiver. Now it's nice and tightI sourced some pipe today, not conduit, and plan on cutting and fitting it on Sunday. I also plan on installing the floor (womanized plywood) and painting it up.Last edited by 46/71 Hybrid; 06-28-2008 at 01:57 AM.
Reply:lol- I think you mean WOLmanized plywood? 'womanized' has some far different connotations.    ...though if you WERE doing some 'womanizing', feel free to send pics of that too!  Lincoln AC225 & MigPak 140, Lincoln Magnum SpoolGun, Miller Spectrum 375-X Plasma, Syncrowave 200 TIG, Millermatic 252 MIG, Miller Digital Elite, General 7x12" horiz/vert bandsaw, 3' box/pan brake, 20 ton press, milling machine, 12x28 lathe, etc.
Reply:Oops, my mistake on the misspelling. I have to say I like my version better though