Build a Headache Rack
Bulkhead (Headache rack) A strong wall-like structure placed at the front of a flatbed trailer (or on the rear of the tractor) used to protect the driver against shifting cargo during a front-end collision. A bulkhead may also refer to any separator within a dry or liquid trailer (also called a baffle for liquid trailers) used to partition the load.
Building a headache rack is not an extremely hard task and is relatively cheap. All you need is {{safesubst:#invoke:convert|convert}} of {{safesubst:#invoke:convert|convert}} square tubing, {{safesubst:#invoke:convert|convert}} of 1/4 x 1 1/2 inch strip of metal, a welder, and a chop saw.
Steps
- Cut the top of the crossbar to the length of the top of your cap or on a 1991 Ford cut at {{safesubst:#invoke:convert|convert}}.
- Cut two sides at 35 degrees at both ends going opposite directions at {{safesubst:#invoke:convert|convert}} in length.
- Tack where the sides angle out. Take and check how it fits on the pickup truck.
- Cut two more pieces (21 inches long) to place on each side of your slider window. If there's no slider window, go 1/3 of the way in from each side.
- Tack and check once more.
- Cut your {{safesubst:#invoke:convert|convert}} x {{safesubst:#invoke:convert|convert}} flat strap into 4 x 6 inch pieces.
- Tack the end pieces on to run with the bed flush to the front of the rack. Take the other two pieces, center, and tack them running with the cab.
- Drill your hole in both rack bases and bed to line up and bolt.
Tips
- Take your time, use common sense, and don't worry if pieces don't fit. Try make larger pieces and go a little smaller each time until they fit.
Warnings
- Dimensions may not fit your pick-up.
