Pick Up Truck Headache Rack

   / Pick Up Truck Headache Rack #1  

GeneD14

Veteran Member
Joined
Jul 29, 2003
Messages
1,458
Location
Tennessee
Tractor
Kubota B26 TLB, Allis Chalmers D17 series IV, Kubota ZG-23 Mower, Kubota ZD 1211, Kawasaki Mule 610, Stihl 361, Stihl 045 AV Super, and a Stihl 660 Ported and tuned
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.
 

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  • 838632-Headache Weld Jig.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#2  
For a cleaner and more professional appearance I welded caps on the end of the tubes that would not get covered.
 

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  • 838634-Headache Cap Tube.jpg
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  • Thread Starter
#3  
Then I used a 4 1/2" disc grinder with a sanding flap wheel to smooth over the welds.
 

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  • 838636-Headache Rach 1.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#4  
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.
 

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  • 838640-Headache Louvers Tacked In.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#5  
My truck has a kind of western theme so I added some horse shoes for good luck.
(insert your own red-neck joke here)
 

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  • 838652-Headache Rack Horse Shoe.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#6  
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.
 

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  • 838654-Headache Rack Final Assy Jig.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#7  
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.
 

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  • 838657-Headache Rack Tab for tool Box.jpg
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  • Thread Starter
#8  
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
 

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  • 838660-Headache Rack Primer.jpg
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  • Thread Starter
#9  
Now for 3 coats of gloss black paint.
 

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  • 838663-Headache Rack Painted Black.jpg
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   / Pick Up Truck Headache Rack
  • Thread Starter
#10  
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.
 

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  • 838666-Headache Clamp to Bed.jpg
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