Headache rack (truck)
Cab-protection rack frame with vertical bars that bolts to the bed rails.
- Size
- 60" × 36"
- Skill level
- AdvancedVehicle or towed frame
- Pieces to cut
- 13
- Steel
- About 37 ft, 2 sticks to buy
- Plan price
- $4.99, yours to keep
Steel you'll need
- 1×1×0.083 (14 ga) square tube7 pieces
- 2×2×0.120 (11 ga) square tube6 pieces
Also buy
- Bed rail clamps or stake-pocket mounts
- Bolts
What the plan includes
- A cut sheet: every piece drawn to scale with tip-to-tip length and the saw setting for each end
- A shopping list and a cutting plan that gets every piece from the fewest sticks
- Build steps: what to tack first, how to check square, and a weld order that keeps it straight
- A 3D model you can resize — change a size and the cut list follows
Safety note. Safety-critical: a frame layout only — not an engineered or tested vehicle. Have a qualified person check it before anyone rides it.
