Headache rack material
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Cargo Master
Joined: Oct 2010
Posts: 2,339
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From: Lost In a Pit of Despair
Headache rack material
I was going to make my own headache rack/roll bar this summer, but I am at a loss for what material to use. Going to design it for looks, and have spaces for front and rear facing fog lights, a bed flood light bar, and a spare tire. Welding using a tig/mig welder
Fleet Owner
Joined: Dec 2009
Posts: 20,678
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From: NorCal
Got a bender???? It'll look more professional if you do...
.095 wall DOM tubing if you can find it for a good price. Otherwise, .125 square or .120 wall round steel tube.
Personally, I like a combination of 2-inch and 1.5 inch tubing... looks more proportional.
.095 wall DOM tubing if you can find it for a good price. Otherwise, .125 square or .120 wall round steel tube.
Personally, I like a combination of 2-inch and 1.5 inch tubing... looks more proportional.
Senior User
Joined: Apr 2010
Posts: 248
Likes: 1
From: Farmington, New Mexico
I've seen several that were made with 2x2 square tubing, but not in the conventional way. Instead the vertical and top horizontal bars are rotated 45 degres so that the corners are on the top/bottom and left/right sides. (did that make sense?)
They look really nice and I will probably go this route myself whenever I get around to building one.
They look really nice and I will probably go this route myself whenever I get around to building one.
Fleet Owner
Joined: Dec 2009
Posts: 20,678
Likes: 82
From: NorCal
Amazingly, YES!
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Cargo Master
Joined: Oct 2010
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From: Lost In a Pit of Despair
Ohh... I don't have a bender.... Was planning on just using elbows, but it would look kinda funny
I was wanting to use square tubing, because it was going to continue down the sides of the bed (on top), sorta like a bed rail.
I was wanting to use square tubing, because it was going to continue down the sides of the bed (on top), sorta like a bed rail.
Senior User
Joined: Feb 2011
Posts: 192
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If you are using square tubing just use pie cuts to get the curve you want if you can't get it bent. Works for round tube too but won't look good.
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From: Lost In a Pit of Despair
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