I've put together some models of back racks. I personally don't really like the crosser bar on the Back Rack brand with the flimsy looking tube and flat bar over the reverse/brake cab light so I designed my own and hopefully will be able to get it built.

I'm leaning towards the 3rd option.

 

I like the framed ones with mesh inside. like Shane's and Tre's

 

Personally I like the headache racks also like Shane's, but seeing as last night I have started rebuilding mine for the 3rd time, I have some advise. First, if you don't like the factory built mounts (which I didn't either for my toolbox) you will definitely need some sort of cross bar like square tube or the like with some kind of gusset. Reason being with out that it will want to shake back and forth and not be very solid at all (ask me how I know, my first one was an angle iron frame around the front of the box with the back rack uprights welded in the center, sorry no pics). Second, ALWAYS measure twice and cut once. Nothing is worse than cutting up good steel to have made a mistake. Also plan it out well, think of everything you want to put on it ect. Make a list. It will come back to haunt you if you don't, like I said, I'm rebuilding mine for the 3rd time because I didn't think it through good enough. Look at some other people's who have made them, factory built ones ect. Third, I recommend sandblasting it or getting it done. I am extremely happy I did and it isn't that bad for price either. Spray primer on the damn thing, it will save you headaches later on. I didn't and even had mine sandblasted and painted with rust paint and it had started surface rusting in a matter or 3-4 weeks. Also use good paint, again-very worth it later on. Lastly I recommend putting weather stripping on the bottom of the rails that sit on the box to keep it from rubbing and making noise and protect the paint.


Also now I see you from Ontario, so am I, if you are anywhere near London you are quite welcome to come look at mine to see how it's mounted ect or even for a visit or if you need a hand I don't mind helping.

 

Thank you for the reply Dave.

I am pretty set on the design I have. I have redesigned it a few time and actually have experience with design as I used to work for a company who built attachments for construction equipment (claws, buckets, hammers, grapples, etc)

Every thing is and will be built heavily within reason for the size of our trucks. The rails on my truck are bed lined but extra weatherstripping wouldn't hurt. It isn't really the mounts I do not like it is the actually bar that will house the lights in my situation. That piece will either be burn on a plasma, spot faced and bent properly in a press, or milled out of a piece of 4x2 rectangular tubing as I have it designed.

Actually building it isn't the problem as I will be doing it at work with some help from the machine shop guys as I do not have my own equipment as much as I would like.

And it will be prep'd properly as I have access to a good resource who runs the paint line at my facility. One thing I hate is doing this half a$$ed. Please don't think I am being a$$. I'm actually at school in Hamilton and working in Guelph

 

Here is an Dimetric Pic

 

I see what you're saying now, I thought you meant the crossbar that the whole thing is mounted on, and it sounds like you've got the design and process of building it under control. I had to make mine with an angle grinder, a chop saw, stick welder and cutting torch. As far as me thinking you were going to do it half azz I never really didn't think you were going to since seeing your plans you made but I just wanted to try and keep you from making the same mistakes I did, I never you knew you had all the resources at your disposal that you do. I wish I had all that when I built mine but I got er done too. Looks like yours should be pretty solid and well built.

 

Does any body know of any 2.5 Inch Whitle LED lights that would fit into my back rack. I currently have two that would work just fine and can order more but I was wondering if someone knew of something brighter. I have M4 series marker lights off of superbrightleds.com