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  #1  
Old 04-19-2011, 08:55 AM
FX4 FX4 is offline
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Default Headache Rack

So since i got my welder, I figured I want to change the look of my truck. I have always wanted a headache rack, but could not justify spending the money on one, so I'm going to make one! Decided to add back up lights the are going to be mounted between the rack and the cab, as well as 4 lights on top.

Here's the plan I made with google sketch up:




While cutting my light mounts, I decided to make some web accents for the parts what will hold up my lights, not the best execution, but I think they can be cleaned up and made work. Make them out of rivet shafts/mandrels (not sure what they're called) and wire hangers. Was also thinking of adding this web design gussets to the bottom of the rack where it will get welded to the angle....







so far I have spent $0.00. I got my light mounts, steel grate/screen for the back, now I just need some 2 inch square tubing.

For those of you with light racks or lights mounted similar to mine here,how did you run the wiring? Did you drill the rack/bar and run all wires inside? How did you run them in the bed to the cab? Thanks and any pics would help; I just want to make it look as clean as possible.

Rafal
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  #2  
Old 04-19-2011, 09:17 AM
FX4 FX4 is offline
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Default Re: Headache Rack

bad diagrams
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Last edited by FX4; 04-19-2011 at 10:50 AM.
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Old 04-19-2011, 09:23 AM
pooleo pooleo is offline
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Default Re: Headache Rack

I think you can wire them to your revers lights, then just run another power from a switch to the light side of the power from the reverse power. This way you can power them with the switch and reverse, tho the switch may also power up the reverse lights...im not a electrical genious, this is just my thought
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Old 04-19-2011, 10:04 AM
btm757 btm757 is offline
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Default Re: Headache Rack

Make sure you use a Relay. Please use a relay so your truck doesnt burst into flames.
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  #5  
Old 04-19-2011, 10:13 AM
FX4 FX4 is offline
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Default Re: Headache Rack

Quote:
Originally Posted by btm757 View Post
Make sure you use a Relay. Please use a relay so your truck doesnt burst into flames.
forgot to add that one there... there will be SPST relays on for both lights


found a diagram for adding the reverse with switch: looks like I'll just need a SPDT relay for the reverse
http://support.kchilites.com/index.p...ch&attach_id=1

diagram for the aux. lights: needs 2 spst relays
http://support.kchilites.com/index.p...h&attach_id=17

Rafal
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Last edited by FX4; 04-19-2011 at 10:49 AM.
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  #6  
Old 04-22-2011, 07:53 PM
FX4 FX4 is offline
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Default Re: Headache Rack

made some progress with the rack today. Made 2 more light mounts, 1 more left to finish up:



Cut and tacked on all my pieces. All that's left to do is remove the steel grating, weld everything together, prime, paint, mount and wire lights.... seems like the easy part was over.

No rack:



Bottom portion:



All tacked up:




My buddy still hasn't returned my magnetic angle finder, so I made this to cut my angles with (I know it's kinda ghetto, but worked out perfectly!):





If anyone wants to make a rack like mine, I would be happy to edit my diagrams with measurements. So far I'm about 7 hours into the rack, and spent a total of $65 (25 feet of 1.5" square tubing was all I had to buy so far). Still need to buy lights....

Rafal
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  #7  
Old 04-22-2011, 08:24 PM
01DangerRanger 01DangerRanger is offline
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Default Re: Headache Rack

great work man!
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  #8  
Old 04-22-2011, 08:26 PM
DiabloBlanco DiabloBlanco is offline
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Default Re: Headache Rack

dude nice!
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  #9  
Old 04-23-2011, 02:34 PM
FX4 FX4 is offline
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Default Re: Headache Rack

got the rack all welded up, grinded the welds, and some more pics:






Rafal
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  #10  
Old 04-23-2011, 02:49 PM
DiabloBlanco DiabloBlanco is offline
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Default Re: Headache Rack

gonna paint it?
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  #11  
Old 04-23-2011, 02:56 PM
brinker88 brinker88 is offline
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Default Re: Headache Rack

It would have been cleaner with tubing...nice work though
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  #12  
Old 04-23-2011, 03:23 PM
FX4 FX4 is offline
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Default Re: Headache Rack

Quote:
Originally Posted by brinker88 View Post
It would have been cleaner with tubing...nice work though

not a fan of the round tubing look, i had some available to me.

----------

Quote:
Originally Posted by DiabloBlanco View Post
gonna paint it?
yes,it's going to get painted with self etching primer and black paint.
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  #13  
Old 04-23-2011, 05:08 PM
stephen stephen is offline
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Default Re: Headache Rack

Normaly I hate the square tubing racks but yours looks great. Nice work.
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  #14  
Old 04-23-2011, 05:41 PM
AlxGry AlxGry is offline
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Default Re: Headache Rack

pro looking job congrats
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  #15  
Old 04-25-2011, 09:59 AM
FX4 FX4 is offline
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Default Re: Headache Rack

scored some self-etching/ rust preventative primer from a buddy so I got a coat of that on:



Started on the switch panel inside:

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