NS Gearhead
Veteran Member
Dunno if this belongs in projects or in welding...
Picked up a tri-fold tonneau cover for cheap... I was pretty stoked until I found out I couldn't get a headache rack that would work with it. Thought about doing something that just sat in the stake pockets, but then came up with this.
Basic shape
Started with 3.5"x3.5"X3/8" angle. I know it's very heavy, but it was free.
Test #1
Amazing how much stress is left in the tubing when it's cut. Oh, it's 2" square 1/8" wall
Cutting out the other side to re-weld
Tried to get a little fancy... not sure if I like it.
I used another length of square tubing and clamps to make sure it was straight when I welded in the cap
Lots of measuring, checking angles, trimming, etc
Test fit #2
Can you see the mistake? LOL
At first I was going to weld angle iron tabs under these uprights, but decided to notch and angle them like this
2x2 screen. 3/16" round stock.
Added 4 u-bolts I had kicking around. I like the bottom ones, but not thrilled at the look of the top ones. I should have drilled two holes and sunk them in. Hopefully they don't show too badly once they're up there. I may put some seam sealer by the threads to pretty them up a bit.
That's where I'm at so far. Still have to make some light tabs, then primer and paint. So far I've got two weeks (maybe 15 hours), and $26 into this. I weighed it and she's a portly 126lbs. That's what you get when you use what you have kicking around.
Picked up a tri-fold tonneau cover for cheap... I was pretty stoked until I found out I couldn't get a headache rack that would work with it. Thought about doing something that just sat in the stake pockets, but then came up with this.
Basic shape
Started with 3.5"x3.5"X3/8" angle. I know it's very heavy, but it was free.
Test #1
Amazing how much stress is left in the tubing when it's cut. Oh, it's 2" square 1/8" wall
Cutting out the other side to re-weld
Tried to get a little fancy... not sure if I like it.
I used another length of square tubing and clamps to make sure it was straight when I welded in the cap
Lots of measuring, checking angles, trimming, etc
Test fit #2
Can you see the mistake? LOL
At first I was going to weld angle iron tabs under these uprights, but decided to notch and angle them like this
2x2 screen. 3/16" round stock.
Added 4 u-bolts I had kicking around. I like the bottom ones, but not thrilled at the look of the top ones. I should have drilled two holes and sunk them in. Hopefully they don't show too badly once they're up there. I may put some seam sealer by the threads to pretty them up a bit.
That's where I'm at so far. Still have to make some light tabs, then primer and paint. So far I've got two weeks (maybe 15 hours), and $26 into this. I weighed it and she's a portly 126lbs. That's what you get when you use what you have kicking around.
