Headache Rack Build

[Wayne M.]

I really like the top rails and how that looks!
Are you running the wiring down a stake pocket In back?

 

[Wayne M.]

Was reading another thread on another forum about welding. The topic turned to metal prep and what to use. Then the warnings began about using break cleaner.
I knew this was bad, and the fumes are dangerous, but didn't know why. Seems that combusted brake cleaner at that high temp causes fosgene gas. Which is lethal. Just a PSA.

 

[Deleted member 995608]

That looks great! How much do you think it weighs? I've got plans to build a rack for my pickup when I get some time. I just haven't decided what it will look like, yet.
I had a Lincoln 256 follow me home in December. I love it! Neither of my stick welders has been turned on since.

It weighs far too much. I used 3/16" wall for the 3x2 tube that makes up the rack. Way overkill. You'll like the 256. My Miller mig gave up last summer and I replaced it with the 256. Took a little trial and error to dial it in, but so far, so good.

I really like the top rails and how that looks!
Are you running the wiring down a stake pocket In back?

Most of the wiring is internal. Only wires that will be visible are for the LED backup/work lights, which will have the GM style 2 pin connectors attached for the ease of replacement; if necessary. I use the standard 4 wire trailer harness wire contained in a round sheath. Not glued flat 4 wire stuff. Most will be soldered connections.

Was reading another thread on another forum about welding. The topic turned to metal prep and what to use. Then the warnings began about using break cleaner.
I knew this was bad, and the fumes are dangerous, but didn't know why. Seems that combusted brake cleaner at that high temp causes fosgene gas. Which is lethal. Just a PSA.

I've used break cleaner in the past without trouble. But I typically do all my welding towards the entrance of my shop, or outdoors. In the old days, break cleaner contained some real nasty stuff, but most of that has been removed from the can. Nonetheless, acetone has become my choice of cleaner. I generally cut my pieces, de-bur, then deep clean with acetone before welding.

 

[Dan_69GTX]

Let me know how you like the LED worklights. I bought a pair locally (don't remember what brand) and the "work / flood" was more of a spot. Took them back and got standard old tractor flood lights. I'd still like to find a set of LED since they use less power and should last longer.

 

[w6pea]

That rack looks better every picture you post. Congrats.

 

[Deleted member 995608]

So I got the brake-turn-running lights tied into the OEM harness early tonight. I ran wire all the way back towards the rear and soldered into the trailer wiring using Weather Pack connectors. I'm vey nervous about tapping into these trucks, but I figured where I tapped in, was the safest place.

I'm 100% satisfied with the LED work lights! So much better than any other halogen work light I've used in the past. The $100 investment has paid off....

Our inter web sucks tonight. Will try loading pics in the AM

 

[Deleted member 995608]

Hopefully the pics will come through now. The work lights from Superbriteled.com are 100% better than expected.

All that's left is to locate a place to mount the Painless fuse/relay box, and mount a switch to run the work lights.

Drove to Nor Cal yesterday morning to celebrate my 40th with some ole lifelong friends. Received lot's of compliments on the rack and lights......tooting my own horn . Back home tonight and enjoying a glass or two of red.

 

[w6pea]

Hopefully the pics will come through now. The work lights from Superbriteled.com are 100% better than expected.

All that's left is to locate a place to mount the Painless fuse/relay box, and mount a switch to run the work lights.

Drove to Nor Cal yesterday morning to celebrate my 40th with some ole lifelong friends. Received lot's of compliments on the rack and lights......tooting my own horn . Back home tonight and enjoying a glass or two of red.

Pictures look great. Happy 40th. Hope you had a great day.

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[Wayne M.]

Very nice. Let's see some completed shots when you get a chance. And happy 40.

 

[jhenderson]

The lights are a great find. LEDs have come a very long way.

 

[Wayne M.]

The lights are a great find. LEDs have come a very long way.

In my shop, they're replacing the mercury vapor hi bays with 120w 5 LED's as the old ones burn out. They have an excellent daylight rating and are bright.