Headache Racks

So customization season is right around the corner! Im thinkin one of my goals this summer is going to be to build a custom headache rack for my truck, and maybe a prerunner bar for the front bumper to and throw 3 or 4 KC's on it. But the headache rack is my main interest. Ive been checkin out pics on google and i think im gonna do the rack with the cutout in the middle for the slidin rear window, and have louver horizontally on the sides and a set of white LED's as back-up/bed light and a set of red LED's as running/brake lights. Heres what im thinkin.. But if anyone has ideas/pics/plans/measurements/materials used for their headache rack, share em please!

http://www.propickupmag.com/files/2012/03/racksUntitled-1.jpg
http://www.tumbleweed-mfg.com/images/headache/headache_4.jpg
http://www.truckaccessoriesdirect.com/images/headache-rack.gif
http://www.tumbleweed-mfg.com/images/headache/headache_1.jpg

I had planned on making one last summer and never got to it
2x4x.120" steel tubing seemed pretty typical

I personally love the spyder industries ones. Always loved the look of a headache rack. maybe some day when I get sick of the stickers.

like this one,

http://www.spyderindustries.com/build_a_rack.html#!/~/product/category=322188&id=6456790

I ended up with a Westin HDX rack. I thought about building my own, but for the price of steel, I think I probably broke even (or even came out ahead) with the deal I found online. I built one on my first truck that turned out really well, but it was basically free because somebody gave me the steel.

Very happy with the HDX rack, very stout and a lot of steel for the money.

Westin Automotive - HDX Headache Rack - NEW!

I agree that 2x4 steel is pretty common for the uprights.
After being around my buddy who has built quite a few, may I make the following suggestions:

Use C-channel to cover the entire length of the bed rails. The size of channel depends on the truck, 2nd Gens have a relatively narrow 'cap' compared to say a 4th Gen.

Make your uprights out of something BEEFY. He went with 5x3 tubing on his 3rd Gen Cummins, and while it sounds totally excessive, it looked GREAT!

Louvers are great, but the visibility really sucks through them (IMO). I'd use grate of some sort personally.

Oh yea... Add lots of lights, then a few more. Lets face it, lights are cool!
Be sure to post pictures as the build happens!

Ryan66, idk that id want to spend that much on a rack though lol but i do agree, that looks badass !

Dogcar3, I actually really like the looks of that one, Ill have to search around and get an idea on pricing and whatnot...although it would be fun to build my own so maybe ill just use that one for a template/ideas. Well see though lol

WhiteExpress, Thanks for the suggestions ! I think if I do decide to build one, ill run steel over the bed rails as protection and make it all one piece with the rack. And of course Im gonna put lights on it haha lights are great! Oh, and I like the look of the louvers..but I have thought about using expanded metal instead. But then again, I never really look out my back window anyway, I usually always use my side mirrors.. And ill be sure to take pics as it is built too

This is what my dad has on his ferd

wermbang said:

This is what my dad has on his ferd

Click to expand...

I was lookin at those backracks too, but I think i want something with more metal to it. But I do like the looks of those also.

Here's my buddies.




He's got a flat bed on it now so it took a while to dig up the pictures.