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Old 08-28-2018, 12:34 AM   #1 (permalink)
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Building a custom headache rack. Need advice!

I'll be building a custom headache rack for my 16' SCREW, need some input from the hive mind.

The rack will be made of 2" square tube (.125 thickness). It will be sprayed with Line-X when I drop the truck off to get the bed and running boards sprayed.

It will be a functional rack as I need the ability to haul lengths of wood/metal/ladders/etc.... With my last truck, I found that I really needed some bed lighting for work. I will be adding some LED flood lights to the top two inner corners and running a switch from inside the cab. I'm looking really hard at using a pair of RIGID flood "pods" over getting some of the cheaper 30-40$ LED lights on amazon.

1. Is it worth the trouble to hide the wiring inside the rack? I'm thinking not, as I will need to deal with figuring out waterproof openings for the wires to enter/exit through and replacing lights will be much harder. I was thinking of just welding small loops on the backside and using zip ties to route the wiring on the back face of the rack. I'll be using shielded 16/2 cables so it will look pretty nice anyway. Opinions?

2. I'll be designing around the need to keep my 3rd brake light exposed. I don't see any reason to add in any extra brake/turn/backup lights on the rack, if they are not needed?

3. Is there anything that you wish you had fabricated onto your headache rack that you don't have now? Looking to 'future-proof' as much as I can.

Thanks for any input!
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Old 08-31-2018, 01:22 PM   #2 (permalink)
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Sound like you need a ladder rack more than a headache rack.
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Old 08-31-2018, 02:10 PM   #3 (permalink)
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Just something neat that I've been seeing lately around TX/OK; some place is making headache rack/bed rail combos with mini hammer unions at the front and back corners with a removable back ladder rack bridge that can be stored on the front unions when not hauling ladders or pipe joints or tools or whatever. Food for thought.
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Old 09-04-2018, 01:56 PM   #4 (permalink)
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I will probably be making matching rear 'hoop' for hauling really long items. I'm not sure if I would need some connecting bars to attach the front 'hoop' to the rear for strength?
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Old 09-15-2018, 11:51 AM   #5 (permalink)
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Here's what I got so far...

The bar across the top got a little ark in it from grinding off some old welds. I got a bunch of 2x2 tube delivered, so I'll probably chop it off and weld on a nice straight piece.

I'm using some Rigid brand pod lights for the two corners, and I'm trying to figure out the best way to run the cables. I'd hate to chop the nice plugs off just to hide the wire runs. And what about making the holes the wires pass through watertight?



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Old 09-16-2018, 10:09 PM   #6 (permalink)
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Old 09-17-2018, 12:07 AM   #7 (permalink)
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Last edited by Beat95YJ; 09-17-2018 at 12:10 AM.
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Old 09-20-2018, 04:03 PM   #8 (permalink)
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Old 09-24-2018, 10:39 PM   #9 (permalink)
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The service truck in front of mine has a fabricated bed box for hauling parts. The rack on top is just two mini headache racks bolted to the roof of the bed box. It won't hold anything heavier than the aluminum ladders on there now.
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Old 09-24-2018, 10:42 PM   #10 (permalink)
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I'm in the last stages and about to send it off for some linex. Trying to find a good way to seal the hole where the wires enter the tubing. I ordered up some metal cable glands. Was wondering if there was anything else on the market?
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