My Headache Rack

[MadManAndrew]

After searching and searching and searching, I finally decided to build my own headache rack since I didn't like any that were on the market. Took me almost 4 months since I rarely worked on it, and never really spent much time on it, but it's pretty much done now. Just need to finish the light bar for my KC lights. So here it is:

Picture 1: I didn't like the looks of the square ends on the bed rails with the rounded ends on the actual bed, so I made a template and copied into on the rails with a cutoff wheel. Obviouslythe rails are full length.

Picture 2: I extended the center posts down to the bottom of the angle for added strength.

Picture 3: I attached it on the inside of the bed using three 1/2" round head bolts.

Picture 4: The rack itself. I put on five brake lights, two ambers, and two reverse. The are EXTREMELY bright. The reverse lights are almost as bright as the freakin' head lights. I also tapped the bolt holes for the toolbox in the bedrails so that you have to have the box open to get it off. I primed it with Rustoleum self-etching auto primer and then painted it with Rustoleum Proffesional Grade Gloss Black enamel. Pretty impressed with it for a spray can but for the life of me I could not get it to stop laying orange peel.

The bed rails are 3x2x1/4" angle, along with 2x2x1/4" up front, and the tube is 2x3x3/16" rectangle. I also put 8x3/16" flat stock across the front and to my surprise it welded on pretty easy.

Overall, pretty satisfied with it. What do you guys think?

[MadManAndrew]

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[kylep]

Looks good, that is a real nice truck ya got there.

[MadManAndrew]

Thanks. I try, lol.
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[MadManAndrew]

After looking at it today, I decided that the Amber turn signals on the headache rack, while they would look good with my stock 2002 tails, do not look good with the '03 tails. Whenever I get some extra cash I'm going to replace them with another set of reds and wire them into the stop/turns. Look kinda like a Mustang.
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