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Discussion Starter · #1 ·
This is a headache rack I am building on a really tight budget. So far I have only 40.00 in material. I had to buy some more 4 x 2 x 11ga and 1/4 Flat stock x 3" wide. I had some 4 x 2 and expanded metal laying around from a previous project I did for someone. Here is the start of the build up for my '02 F-250 Superduty. Again, nothing fancy just a headache rack that will hold my strobes, flood lights and maybe some other lights I have laying around.

Ok. Here we go:


I was able to find the angle of the cab with this great tool. Digital anlgle finder.



Then I cut calculated how high I want this thing to be and cut the uprights to the proper angle. Remember you are cutting from 90 degress. I wanted the uprights to be at 71 degrees so I made the cut at 19 degrees.



Here is the upright.



More pics next post.

T.J.
 

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Discussion Starter · #2 ·
Cont'.

Here is the Strobe Eccho set up I will be using. I also have a plate that it will bolt to. There also will be some sort of anti-theft/branch protection strapping for it too.




These are the 12x5x 1/4" base plate. Notice the holes in this stuff, again more scrap. These plates cover up the front stake pockets. So I will machine a hole in them so I do not loose the functionality of the stake pockets.
 

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Discussion Starter · #3 ·
Cont'.

Machined the plates for the stake pocket and also did more simple geometry for the miter cut for the top piece. I mocked it up with wood just to make sure my angles were correct. The digital level reads in 10ths. So you really can't get more level than that (0.7). Yay my math worked. Here are some pics. And, I still only have 40 bucks into this thing.
More of the budge headache rack coming soon.
T.J.









Pics Cont. Next post.
T.J.
 

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With all that money invested in tools I can see why you can't afford a Back Rack! :wink:D
 

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Some of us enjoy spending money on tools not toys and building things the way wewant them not the way some office big wig thinks we want them.
 

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Discussion Starter · #8 ·
With all that money invested in tools I can see why you can't afford a Back Rack! :wink:D
Yes you are right my tools are a big investment that allow me to work smarter and more efficiently, thus potentially creating a greater return on investment.:D
Really I just want to show this can be done with scrap I had laying around without spending much and building it the way I want it built.
T.J.
 

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Trust me I get it. I am always modifying things to make them "right". I was just Kidding around!
 

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Trust me I get it. I am always modifying things to make them "right". I was just Kidding around!
Matt...

TJ is no joke this guy is amazing. He has done some wild fab work from trucks to Mustangs to Jet Boats :drool..........


IMO there is nothing better than seeing someone take an idea from what is already being mass produced and making it better and on their own and it coming out super nice like TJ's work...


Jay
 

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TJ very nice work one question for you; the holes for the stack pockets did you have to mill that out completly or were you able to just go around the edge of it and end up with a rectangular piece for a scrap or just metal shavings?
 

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Discussion Starter · #12 ·
TJ very nice work one question for you; the holes for the stack pockets did you have to mill that out completly or were you able to just go around the edge of it and end up with a rectangular piece for a scrap or just metal shavings?
Hehe. Funny you ask that. I milled around the edge and have the pieces. I am going to use these pieces that will act like large washers and pinch the top plate to the bed when I bolt it down.
T.J.
 

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Hehe. Funny you ask that. I milled around the edge and have the pieces. I am going to use these pieces that will act like large washers and pinch the top plate to the bed when I bolt it down.
T.J.
I was goingto suggest that if you hadnt already thought of it :D
 

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Discussion Starter · #14 ·
Update More progress and pics.

Worked on it more today.

I was able to tack it alltogether on the truck. Here it is in the garage.



Clamped it to the bench for a full weld of the joints to eliminate movement.



All tight and ready to weld.



Full weld.
 

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Discussion Starter · #15 ·
Another shot. I also smoothed out the outside corners for painting.



Stood the rack up on the bench and tacked it down for a full flange weld.



Ready to go. Both sides are tacked to the bench.



Full weld.
 

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Discussion Starter · #16 ·
Letting it cool fully. Had lunch.



Mock up test fit. It did not move too much the bolts still line up...



I will round the corners when ready.



Shot from the back. I left it high because there willl be a light panel too.
 

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Discussion Starter · #17 ·
Outside corners are smoothed out.



Stay tuned for the light panel and the expanded metal fitting. Oh and I still only have 40 bucks of material into this thing...

T.J.

www.tjsperformance.com
 

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Lookin' good! You wanna make one for me for $40? :drool
 

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Yes you are right my tools are a big investment that allow me to work smarter and more efficiently, thus potentially creating a greater return on investment T.J.

Something that Steve taught me very early on in our marriage (I think it was when I said something of a negative nature about an unscheduled stop at Tool King), and he drilled this into me until I had nothing but encouraging words regarding any tool purchase:

"TOOLS DO NOT COST MONEY. TOOLS MAKE MONEY."
 

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Oh, and BTW, nice welds! :shades How do I teach my welder to make 'em pretty like that! :D
 
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