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Head Ache Rack Budget Build

Discussion in 'Equipment, Tools & Vehicle Pictures' started by TJS, Sep 29, 2009.

  1. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    I needed to make a head ache rack that will protect the back glass and make a nice mounting spot for my light bar and other strobes along with back up lights. This is a budget build as the title states. I am using the scrap I have laying around. I have spent so far $0.00 to this point. I machined the mouting plate for the light bar (no pics). I cut the uprights out of 4x2 rect. 10gauge. I also cut the mounting plates for the bed. I had all this steel laying around. I already have the expanded metal (cage) to protect the glass laying around. I need to get a few feet of more 4x2 and some 3" flat.
    Stay tuned. I will document the build as I progress.

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


    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 72 degrees so I made the cut at 18 degrees.
    [​IMG]


    Here is the upright.
    [​IMG]



    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.
    [​IMG]
     
  2. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    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. The digital level reads in 10ths. So you really can't get more level than that. Yay my math worked. Here are some pics. And, I still only have 40 bucks into this thing.
    T.J.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  3. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Cont..

    [​IMG]

    [​IMG]
     
  4. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    I was able to tack it alltogether on the truck. Here it is in the garage.
    [​IMG]


    Clamped it to the bench for a full weld of the joints to eliminate movement.
    [​IMG]


    All tight and ready to weld.
    [​IMG]


    Full weld.
    [​IMG]
     
  5. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Another shot. I also smoothed out the outside corners for painting.
    [​IMG]


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


    Ready to go. Both sides are tacked to the bench.
    [​IMG]


    Full weld.
    [​IMG]
     
  6. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Letting it cool fully. Had lunch.
    [​IMG]


    Mock up test fit. It did not move too much the bolts still line up...
    [​IMG]


    I will round the corners when ready.
    [​IMG]


    Shot from the back. I left it high because there willl be a light panel too.
    [​IMG]
     
  7. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Outside corners are smoothed out.
    [​IMG]


    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.
     
  8. Bossman 92

    Bossman 92 PlowSite.com Addict
    Messages: 1,771

    Now that is nice!! Keep us posted and let us know how it works out. I am intersted in the whole process and would like to make a few for myself.

    Thanks Bossman
     
  9. Steve G.

    Steve G. Senior Member
    Messages: 155

    You do very nice work, your welds are gorgeous... I wish a could do nice work like that. What kind of welder do you have?
    I use the electric lincoln welder and I can't get close to those nice welds... offcourse, I know it not the welder, it's me that's the problem:cry::cry:
     
  10. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Adding at plate that will hold the strobes. This makes them removeable. I am going to weld nuts into the top of the rack. Here is a little trick to hold the nuts flat.

    [​IMG]


    Here is the nut in the hole.
    [​IMG]


    Welded and ready for smoothing.
    [​IMG]


    Here are the nuts welded and smoothed out flush.
    [​IMG]
     
  11. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    Made the light panels for back up lights and strobes. Used my hole saw on the Bridgeport and 11 ga. sheet for the panels.
    I decided today that I was going to add some KC lights to the project I had laying around so I had to make some mounting tabs and weld them on. Yesterday I drilled the all the holes needed for the wire harnesses. I also welded in a lower brace that is going to support the expanded metal. So far I still have 40 or so bucks into this project as most the materials used is scrap I have laying around.
    Follow along as the tabs are fabed up.



    [​IMG]
    Mocked up the rest of the lights and the strobe bar. KC lights ready.


    [​IMG]
    1/4 flat stock for the mounting tabs.



    [​IMG]
    Traced the mounting part for the KC light and transfer punched the hole.



    [​IMG]
    Drilled out both holes using a vice stop so I do not have to refigure the second part.
     
  12. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    [​IMG]
    A little cutting and sanding and all done. We don't need no water jet..



    [​IMG]
    Mounting tab and light mocked up for proper clearance.



    [​IMG]
    Ready to weld.



    [​IMG]
    One down, one to go.
     
  13. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    More...


    [​IMG]
    Second one done.



    [​IMG]
    Another shot.



    [​IMG]
    Yay the lights fit.



    [​IMG]
    Another mock up. Next up plasma cutting the expanded metal and welding it on the rack.

    T.J.
     
  14. mvhauler

    mvhauler Senior Member
    Messages: 170

    VERY professional. It does take a lot of time and patience, doesn't it? The reward is satisfaction of a job well done!
     
  15. TJS

    TJS PlowSite.com Addict
    Messages: 1,345

    I have an HTP MIG 240AMP machine. Great machine by the way. I have used many Miller MIGs and this welds just as good if not better, very smooth arc.

    Also have a Miller Dynasty 300DX TIG Inverter machine with water cooler. This machine is amazing. My favorite. I try and TIG most of the time when doing projects.
    Thanks.
    T.J.
     
  16. Elite Property Services

    Elite Property Services Senior Member
    Messages: 230

  17. mcwlandscaping

    mcwlandscaping 2000 Club Member
    Messages: 2,557

    Beautiful welds, well, just the whole project looks fantastic! That's sort of along the lines of what i wanted to do with my truck but really just didn't have the time but i certainly wouldn't have been able to come up with a final product like that. I just don't have the tools to do it, sure wish i did. Anyway, fantastic product! I'm sure people will inquire about buying others you may make! The time and effort really pay off in the end of a project like that!
     
  18. nickv13412

    nickv13412 Senior Member
    Messages: 621

    i like the use of the 1-2-3 block, theyre handy little things. Very nice welds also, ive been improving on my TIG welding, its definitely my favorite to do. takes patience, but the end result is always worth it when TIGing

    Looks great, very professional work :drinkup:
     
  19. KL&M Snow Div.

    KL&M Snow Div. PlowSite.com Addict
    Messages: 1,616

    Looks awesome! Can;t wait to see that thing ready to go on the truck
     
  20. Banksy

    Banksy PlowSite Veteran
    Messages: 3,113

    You need to mass produce these. Awesome work!