Pick Up Truck Headache Rack

[GeneD14]

I have been toying with the idea of building my own headache rack that would match my front grill guard. I looked at several ones for sale on the internet and decided to use 2" square tube for the main framework.
I laid out the basic shape on a piece of plywood to use as a pattern/weld jig.

 

[GeneD14]

For a cleaner and more professional appearance I welded caps on the end of the tubes that would not get covered.

 

[GeneD14]

Then I used a 4 1/2" disc grinder with a sanding flap wheel to smooth over the welds.

 

[GeneD14]

I then used 1 x 1 angle iron for the horizontal louvers. I cut blocks of wood to use as spacers so they would be evenly spaced.

I just tacked thenm all in place before welding them solid to make sure everything looked straight.

 

[GeneD14]

My truck has a kind of western theme so I added some horse shoes for good luck.
(insert your own red-neck joke here)

 

[GeneD14]

After welding everything up solid I ground all of the butt welds flush and then went over them with the sanding disc to get out any grinder marks.
Then I welded on the 2 pieces of 2" angle that would attach to the bed and hold the rack vertically in place.

 

[GeneD14]

I wanted to be able to install the tool box for my truck with out drilling holes in the top rail. So I welded 2 tabs on to the 2" angle iron that I could blot my tool box to.

 

[GeneD14]

Up here in MI we have alot of rain, snow, and road salt so protecting the steel from rust is a big concern. So for the primer coat I used POR-15.
By the way once it dries on your hands it will have to wear off!! 3 days later and I still have gray blotches on me. /forums/images/graemlins/smirk.gif

 

[GeneD14]

Now for 3 coats of gloss black paint.

 

[GeneD14]

I wanted ot mount the rack with out drilling any holes in my truck bed. So I design a method of 4 clamps that use 1/2" bolts to clamp the rack to the bed rail.