Headache racks and cross bed tool boxes

handirifle · Jul 11, 2012

I was looking for a used box to put on the front of my utility trailer, but instead came across a cross the bed tool box, for my truck. The truck is an '06 Tundra, with a 6.5' bed. I also tow a 5th wheel, and I haven't tried to be sure, but I believe I will have to remove the box, when towing the 5th wheel. I will try the fit out on that, but my main concern for now is that when I make and mount a headache rack for my truck, I will have to move the box back to clear the vertical post of the rack.

I plan on building the rack of 1 1/4" square tubing, welded to an angle iron base, probably something along the lines of 3/`6"x 2x3, or close to that. I want the angle to run the length of the bed rail, with posts going into the stake pockets, and hooks that will lie flat when not in use, yet allow me to lift them and hook a rope or strap to when needed.

When I weld the vertical post to the angle, I am assuming I will need a triangle shaped brace from the vertical to the angle, correct? I plan on using the rack to support anything and everything too long to fit in the bed or stick a safe distance out the back. That will include wood poles, wood beams, extra long PVC, you name it. So a pretty fair amount of forward pressure could end up on the rack.

How do others deal with this when they have a cross bed tool box on it? Do you just slide the box back far enough to clear the bracing, or do you slot or notch the tool box to allow a closer fit? The box is aluminum and I do not TIG weld. If I slotted or notched the box, I would have to fabricate some sort of cover inside the box, to keep it at least fairly water tight.

Any ideas will be appreciated and considered.

schmism · Jul 11, 2012

sounds like you need to remove the stock truck bed and go with a custom (or semi custom) flat bed with built in headache rack. That should give you enough room for tool box plus the fifthwheel hitch.

handirifle · Jul 12, 2012

Well I have no desire to have a flat bed on it, I use the truck for many things and a flat bed will not work well for most of them. Honestly though, I do not see how a flat bed with a built in rack could put the rack any farther forward than I could. There is only so much room before you hit the back of the cab window, and you cannot go right against the cab or else you will ruin the back of the cab. The only thing that would save POSSIBLY is the bracing.

I think if there are no other options, I will remove it every time I tow the 5th wheel or consider notching the forward corners of the box to fit farther forward. I have a friend that's a certified welder, but not sure if he does aluminum or not.

MtHam · Jul 12, 2012

The pictured Back Rack bolts to top of the bed and comes off in about 5 minutes.It has minimal space between it and the window of the cab. It may or may not need to be removed depending on the 5'er. A box could sit under it and be flush with the front of the bed. It functions well for carrying lumber etc.

handirifle · Jul 12, 2012

Interesting rack, never seen one quite like it before. I noticed the bracing is on the square horizontal bar across the bottom. Does the vertical flex much with a heavy load set against it?
i am not too concerned about needing to remove the rack, but rather the tool box. Tool boxes are handy storage, but I may yet just sell it and get abtrailer tongue box like I set out to do in the first place.
otherwise, I will work up either a modded box, or a quick detach setup for the box. I do like having all my straps and ropes etc, out of the cab though. I also see that boxes, at least this one are just deterrents to theft, since a solid pry bar would make access pretty easy. Thin aluminum isn't super strong.

MtHam · Jul 12, 2012

I have not experienced any flexing with loads. It seems to be very strong. Since it is a shortbed, and I do have a 5'er, I am concerned about clearance, although I do have a sliding hitch. Haven't put it to the test yet.

handirifle · Jul 12, 2012

Mine has a slider as well, and it comes in handy when we get shoved into small RV spaces, with everybody and their brother parked in the streets.

techwrtr2 · Jul 14, 2012

MtHam said:
View attachment 273081 View attachment 273082

The pictured Back Rack bolts to top of the bed and comes off in about 5 minutes.It has minimal space between it and the window of the cab. It may or may not need to be removed depending on the 5'er. A box could sit under it and be flush with the front of the bed. It functions well for carrying lumber etc.

Did you have to drill any holes to mount that? I've considered buying one for my truck but have avoided it because it would interfere with a cap... another thing I need.

handirifle · Jul 15, 2012

They make them for caps, I have seen where they havd tabs that extend out from the cap and go up from there around and over the cap. Or at least I have seen racks like that, maybe not headache racks, now that I think of it.