Headache Rack Build

[Deleted member 995608]

I started this about 2-3 weeks back but I haven't had much free time. The bed top rails are 3" x 3" x 3/16" angle which will eventually have a 1" solid rod rail on top, running the length of the bed.

I don't like to see fasteners on a finished project, so I tend to drill & tap bolts into my work to hide the bolt heads or nuts if I can. The 3" angle was tapped for 1/2" - 13 coarse thread bolts. I then weld the backside of the bolt and grind to finish. It was really hard for me to drill holes into my new truck, but I did and now I'm over it. Once it's mounted, all the fasteners will be out of sight for a clean look.

The actual headache rack will be fabbed using 3" x 2" x 3/16" rectangle, 2" x 1" x 3/16" rectangle and some 3/4 - 9 flat rolled expanded metal. I'm going to integrate an opening for some square work lights but I haven't decided if I want regular sealed beam lights, similar to whats used on tractors and such, or LED's. It seems like the affordable LED's are cheaply built and not very bright, and the good LED's like Rigid Industries cost an arm and a leg. I can't see myself paying $300 for lights.

Not too much to brag about yet. I had a small window of time to grab some more steel this afternoon, so I took off without the flatbed and I ended up having to pay a stupid $5 per piece cut fee because I can't haul 20' sticks in my truck..........yet.

 

[mwilson]

Looks like it will be well built.

I have placed a link below for a rack that is made in Maine, you may see a feature or other idea that might be helpful while fabricating away. These are very robust units.

http://www.mainetruckracks.com/index.htm

 

[Deleted member 995608]

Thanks Wilson. Never can have too many ideas.....

 

[Deleted member 995608]

Cut and tacked up these pieces at 4:45 this morning. Just took a lunch break so I through it up to see what it looked like. Could be slightly taller, but these truck are so tall, so I'll leave it where its at.

 

[Deleted member 995608]

Tonight I got the back up light framing tacked up. I also tacked in some rings for various tie down points.

These are the LED lights I chose. They won't be here for a few days, but I'll test them out in the dark to see if they meet my needs. We live in the foothills.... no stop lights, no street lights, et cetera. Backing up can be tricky here, and my Granite Crystal color truck might as well be Black in the dark. I came to depend on my back up lights with my old 3rd gen. https://www.superbrightleds.com/moreinfo/led-work-light-lights/led-work-light-5-14-square-27w/1225/

 

[Wayne M.]

Looks great. Nice fab. Lucky to have space to work.

 

[Deleted member 995608]

Just cut out the 3/4-9 flat expanded metal. Can't finish cut it yet to fit around the lights until I know I'm going to use those specific LED's. May have to cut those out and rebuild for a different sized light. The lights won't be here until Monday. Not a lot else I can do at this point.

I also drilled/tapped for the back light mounting botls.

109 here today so working in the shop is awful.

 

[Deleted member 995608]

Too early to go in the house. I decided to cut out the caps for the lumber stingers on top. Made a quick little template and went to work on my band saw. It's just a Milwaukee porta band mounted to a stand produced by Swag Off-road. Handy tool to have.

 

[jhenderson]

Appears to be a purposeful unit. Everything you need and nothing you don't . I like that. Of course it always appeals to me when these trucks really do work. You're right about LEDs. The worst part is it's getting hard to find good halogen aux lights. LEDs are great but they don't work snowplowing. Being cold the snow builds on them. Halogens stay hot and clear but they're going the way of the dinosaur. Kinda like me.

 

[promisedland]

Love it!
Im a metal fab'er by trade and i luv to make stuff, and see what my friends are making

 

[Deleted member 995608]

I used to do a lot of side work metal fabrication and repairs. But ever since my wife and I moved to run her family business, all that stuff has become near and far simply because I can't dedicate myself to a project like I used to. I'm a horseshoer and a wannabe blacksmith by trade, so anything that involves metal get's my attention. For the longest time, I cut everything with abrasive wheels on a chop saw or angle grinder. It's only been 5-7 years since I acquired my big band saw, or my portaband, plasma, benders etc. I surely appreciate the value in those tools, but I also know that I can pick up the old tools and do the same thing; just takes longer.

 

[jhenderson]

Have you ever considered a circular saw with a metal cutting blade? A guy I grew up with works for a co that builds oil delivery trucks. I watched him cut 4 feet of chassis off new Pete with one. I was dumbfounded. He had it done quicker than you could set up a plasma machine.

 

[Deleted member 995608]

Ya those cold cut saw blades are awesome! If I hadn't spent the money on a Turn Pro bandsaw, I'd have a metal blade chop saw no doubt. Cut's fast and square with no SPARKS! The price of the blades are not cheap, but from what I've read, they last quite a while. My Turn Pro cuts extremely well, but it super slow, so it would be nice to be able to cut faster.

My plasma is a Cutmaster 52. I don't use it as much as I thought so it's kinda of a wasted investment. I mainly use it to cut long lines in flat sheets, using an aluminum square tube as a guide. It's really shines when making oddly shaped holes or cuts in tighter spaces. Psssst, don't tell the plasma fan boys I use my oxy/act torch more than the plasma

 

[promisedland]

treason!
I have a Hypertherm 65 that a great machine. i use it more then my oxy/lp torch though.

 

[Wayne M.]

Hey J, can you please post some detail pictures on the band saw bracket/base? That's very interesting.
Regarding LEDs, we use mostly Trucklite and they're robust and bright. The Wreckers came through with a nice oval LED stop/turn with a chrome backing. They look chrome till they light red.

 

[Deleted member 995608]

Sure thing Wayne. The portaband table is made by SWAG Offroad in Oregon. It comes disassembled in a flat rate USPS box so shipping is cheap. Just bolt it together, mount your favorite portaband and you're in business. I opted for the optional foot pedal control and made my own stand to bring it all up to a decent working height.

I also have the SWAG Harbor Freight press brake kit and arbor plates. I just heavily reinforced the HB press for heavy duty use. I can easily bend 3/8" plate into a 90 for brackets etc. I heated up some 1/2" A36 and tried to bend it into a 90.....didn't do so well. Either way, a great and relatively cheap way to get some awesome tools that most of us will never pay for.

Here's a link to SWAG. Warning! Makes your wallet smaller after viewing: http://www.swagoffroad.com/Metal-Fabrication-Tools-_c_7.html

 

[Wayne M.]

Wow! I gotta get that press brake! Although I have access to a real one (12') at the job. I have the same HB press lol.
Yes the swag looks dangerous like the Eastwood catalog.
Thanks!

 

[Deleted member 995608]

The UPS man dropped off some cool parts today. My backup/work lights came in from SuperbriteLED.com along with my brake/turn lights from Maxxima. I'm pleased with the output of the LED backup lights, so I'm going to use them. Not bad for $50 each.

I wasn't going to add additional lights to the rack, but I'm impressed with shiny things, so I bought some LED's that will fit the 3"x2" tube. The standard 2" round or the 6"x2" oval trailer lights are too large for 3" square tube, so I searched the inter web and came across some accent LED lights that would fit nicely.

My 3rd brake light on the cab will be covered up by the rectangle tube. I'll be using (3) 3/4" round LED lights for a replacement on the backside, along with (2) 1-1/4" red LED's on the outer ends for turn signals. I also bought (2) 3/4" amber LED's to mount on the outside of the upper stingers. Not sure I'll use them, but then again, I'm easily distracted by bright lights and shiny things.

I finished boring the holes for the LED lights tonight. Tomorrow, I have a few business related fixes to do first, but after that, I'll be working on the rack for most of the day.

 

[Deleted member 995608]

I got to spend about 4 hours today on the rack. I hoped for more, but when ya live at your job, the job always finds a way to come first. Anyway, got the 1/2" angle welded in. This is what I'll tack the expanded metal to. It provides a ton of support, plus it makes a clean finish. I then cut and finished the expanded metal to fit the 1/2" angle frame. Fit's good enough for the girls I go with. I also welded the rack all the way around, allowing some cooling time between welds. Tomorrow, I'll bust out the grinder/flap wheels to knock off the sharp edges etc before I tack the expanded metal permanently into position.

 

[Wayne M.]

How do you cut your angles?