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Head Ache Rack on a Budget

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  • Head Ache Rack on a Budget

    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. Here are some pics of what I have done so far.


    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 72 degrees so I made the cut at 18 degrees.



    Here is the upright.




    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.


    T.J.
    Miller Dynasty 300DX
    HTP MIG 240
    HTP 380 Plasma

    Bridgeport Milling Machine
    South Bend Lathe
    Etc. Etc....
    tjsperformance.com

  • #2
    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.







    Miller Dynasty 300DX
    HTP MIG 240
    HTP 380 Plasma

    Bridgeport Milling Machine
    South Bend Lathe
    Etc. Etc....
    tjsperformance.com

    Comment


    • #3
      More.



      Miller Dynasty 300DX
      HTP MIG 240
      HTP 380 Plasma

      Bridgeport Milling Machine
      South Bend Lathe
      Etc. Etc....
      tjsperformance.com

      Comment


      • #4
        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.
        Miller Dynasty 300DX
        HTP MIG 240
        HTP 380 Plasma

        Bridgeport Milling Machine
        South Bend Lathe
        Etc. Etc....
        tjsperformance.com

        Comment


        • #5
          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.
          Miller Dynasty 300DX
          HTP MIG 240
          HTP 380 Plasma

          Bridgeport Milling Machine
          South Bend Lathe
          Etc. Etc....
          tjsperformance.com

          Comment


          • #6
            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.
            Miller Dynasty 300DX
            HTP MIG 240
            HTP 380 Plasma

            Bridgeport Milling Machine
            South Bend Lathe
            Etc. Etc....
            tjsperformance.com

            Comment


            • #7
              Outside corners are smoothed out.


              Made panels for the lights.


              Mocked up the rest of the lights and the strobe bar. **** Cepek lights ready.



              1/4 flat stock for the mounting tabs.




              Traced the mounting part for the **** Cepek light and transfer punched the hole.
              Miller Dynasty 300DX
              HTP MIG 240
              HTP 380 Plasma

              Bridgeport Milling Machine
              South Bend Lathe
              Etc. Etc....
              tjsperformance.com

              Comment


              • #8

                Drilled out both holes using a vice stop so I do not have to refigure the second part.




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




                Mounting tab and light mocked up for proper clearance.




                Ready to weld.
                Miller Dynasty 300DX
                HTP MIG 240
                HTP 380 Plasma

                Bridgeport Milling Machine
                South Bend Lathe
                Etc. Etc....
                tjsperformance.com

                Comment


                • #9

                  One down, one to go.




                  Second one done.




                  Another shot.




                  Yay the lights fit.



                  .
                  Miller Dynasty 300DX
                  HTP MIG 240
                  HTP 380 Plasma

                  Bridgeport Milling Machine
                  South Bend Lathe
                  Etc. Etc....
                  tjsperformance.com

                  Comment


                  • #10

                    Another mock up. Next up plasma cutting the expanded metal and welding it on the rack
                    Miller Dynasty 300DX
                    HTP MIG 240
                    HTP 380 Plasma

                    Bridgeport Milling Machine
                    South Bend Lathe
                    Etc. Etc....
                    tjsperformance.com

                    Comment


                    • #11
                      More. Painted and did some wiring to my home made center console switch box. This will control the 6 head strobes front and rear independently as well as the "tractor lights" and "off-road" lights. I also have my plow controls mounted on here.
                      T.J.







                      Miller Dynasty 300DX
                      HTP MIG 240
                      HTP 380 Plasma

                      Bridgeport Milling Machine
                      South Bend Lathe
                      Etc. Etc....
                      tjsperformance.com

                      Comment


                      • #12
                        Got it mounted on the truck and wired up (what a pain that was). Anyway, the holes I drilled in the plate for the bolts does not work. The head if the nuts or bolts from under the bed does not fit. The heads hit on the sides. Only the front bolt works. So I had to make a sandwich plate and bolt assembly the resembles a back rack bolt set up. I was able to find some bolts laying around and make this thing work. I just need to get some washers . T.J.




                        Miller Dynasty 300DX
                        HTP MIG 240
                        HTP 380 Plasma

                        Bridgeport Milling Machine
                        South Bend Lathe
                        Etc. Etc....
                        tjsperformance.com

                        Comment


                        • #13
                          Pics and ready.



                          Miller Dynasty 300DX
                          HTP MIG 240
                          HTP 380 Plasma

                          Bridgeport Milling Machine
                          South Bend Lathe
                          Etc. Etc....
                          tjsperformance.com

                          Comment


                          • #14
                            Nice job and clean detail work!

                            Comment


                            • #15
                              Very nice !

                              Comment

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