Head Ache Rack on a Budget

[TJS]

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.

[TJS]

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.

[TJS]

More.

[TJS]

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.

[TJS]

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.

[TJS]

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.

[TJS]

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.

[TJS]

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.

[TJS]

One down, one to go.




Second one done.




Another shot.




Yay the lights fit.



.

[TJS]

Another mock up. Next up plasma cutting the expanded metal and welding it on the rack