Headache Rack

[BusaDave9]

I built a Headache Rack (a rear window guard for my pickup). CJ was asking about it so here it is:

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As you can see I also made rails with double bars as support so tie downs wouldn't slide on the rail.
I welded it up with my Millermatic 211

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I then had it powder coated. I don't think you can tell from the pics but I got a textured black.

Next I need to apply a bed liner to the truck. I've already started to prep it.
It's been a busy spring.
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[thiswontbetooexpensive]

Looks nice Busa!

 

[CJ]

You have been a busy Busa D!

 

[Bowbender]

Looks good Dave! That should keep the firewood from bustin' out the back window!

 

[IOPort51]

I am impressed.

Did you cut all that with a hack saw??

Have you started working on the new front bumper and winch mount??

 

[BusaDave9]

Did you cut all that with a hack saw??

I bought a chop saw.

It worked great but it can only cut one angle. When I had to cut square tubing with a double-angle joint (as in the above pic) I would measure the 2nd angle as how many inches to the side the end should be. For example I would set the chop saw to cut a 23° angle and then raise the end of the bar thinking it would also need to go forward 3 inches. I'm sure I didn't make any sense but the short answer is: no, I didn't use a hack saw.

 

[IOPort51]

I understand and you do what ever works.

I have a preference for a band saw It is slower but quieter does not throw sparks everywhere and I think a bit more versatile. mostly quieter.

I bought a chop saw.

It worked great but it can only cut one angle. When I had to cut square tubing with a double-angle joint (as in the above pic) I would measure the 2nd angle as how many inches to the side the end should be. For example I would set the chop saw to cut a 23° angle and then raise the end of the bar thinking it would also need to go forward 3 inches. I'm sure I didn't make any sense but the short answer is: no, I didn't use a hack saw.

 

[BusaDave9]

I have a preference for a band saw

I also have a preference for a band saw. :drool:
My wallet has a preference for a hack saw.
I did a compromise and went for the chop saw.

 

[Bowbender]

Dave, you must have some carpentry experience, looks like the way a carpenter would go at it. ( I are one )

 

[BusaDave9]

No
No real experience as a carpenter. I've worked with wood but not a whole lot.

 

[IOPort51]

did you use some form of CAD??

 

[BusaDave9]

did you use some form of CAD??

No CAD. I just drew it out on paper. Hindsight is 20/20 so there are a couple of things I would have done differently but overall I'm happy with it.
At first I was thinking of just using expanded metal or some other vented plate. That would have been the easy route. Then I decided to use tubular bars at the same angle as the side of the cab. I decided to make a "window" where my rear view mirror lines up. I used flat steel for visibility but interconnected the bars for strength. Before building the rack I drove around with electrical tape on my rear window to verify where my field of view was.