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  1. #1
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default 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. #2
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    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

  3. #3
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    More.



    Miller Dynasty 300DX
    HTP MIG 240
    HTP 380 Plasma

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

  4. #4
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    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

  5. #5
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    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

  6. #6
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    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

  7. #7
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default

    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

  8. #8
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default


    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

  9. #9
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default


    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

  10. #10
    Join Date
    Sep 2005
    Location
    CT.
    Posts
    333

    Default


    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

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