Tubular Bed Rack Build

Back about a year ago, I started work on a Bed rack for my truck. I have always been a fan of the tube style bars, and I needed a real project to use as to push me to learn some CAD and 3d Modeling using Inventor Pro.

After several long nights I came up with a design I liked.






Ok, now I have a design, but I lacked the equipment to build it as designed, and it would involve skills I had yet to acquire, (tube bending and layout ). I started looking for places to cut the flat parts out, and I ended up finding SendCutSend. I uploaded the drawings for the cut files, and received quote, and at the time, I thought it was reasonable, So I went ahead and ordered some parts.

It was about this time I picked up a SWAG off road 20 ton finger brake kit and a 20t press. first of several new tools that would be needed to actually build this.



Version 1 of the bed bar brackets. I ended up having these bent at a local sheet metal shop. and learned the hard way. that my design process was off.



yep, part no fit. it was due to how I modeled the part, I had not yet used the sheet metal tools to design the part and create a flat pattern, so the original design did not take into account the bend and difference it would make in the final part.

Several months later I bought a 3d printer for other projects, and I had learned a bit more CAD and 3d modeling, and discovered how design the bracket using the sheet metal tools.

This time, I was going to be smart about it, after designing version 2 of the bed brackets, I 3d printed a portion of the bracket to confirm fit.





Still, needs to be tweaked a bit, and perfect example of how 3d Printing saved me money on the final part by finding the design flaw before ordering a second set of parts.



after adjusting the location of the slots in the design, I had a design that could be sent off to the laser cutter, again.

Once the new parts arrived, I was able to bend them in my shop using the new finger brake for the 20 ton press I had picked up earlier in the year.





Once again the 3d printer and the ability to create a prototypes to confirm the design has proven to be a highly valuable addition.

Another one of the tools needed to complete this project that I needed to purchas was a tube bender, and to design and build a stand for it.

Building the stand gave me time to practice my welding, Prior to this it had been over 20 years since I did any welding.





Not weld porn worthy, but I am pleased with them, after only a couple hours of practice, AND teaching myself TIG at the same time. all previous welding had been stick.






Air over Hydraulic to save the shoulders, and lets me put the bender on a rolling stand to get it all out of the way when not needed.

It was finally time to buy some tube.. When I called the local steel yard to check prices on 1.75" HREW tube, they informed me they did not have it in stock, and would have to order it. So out of curiosity I asked if they had it in DOM. turns out it was in stock at another warehouse a few hours away, and they could get it to me the next day. and I could get get it at the previous price, before the new pricing took effect on the in coming shipment . I was able to pick up the DOM tube for nearly the same price as what the special order for the HREW would have been. So i decided the bed rack was getting an upgrade, and I ordered 2 sticks



Layout and bending tube was a completely new skill set for me, I had watch some youtube videos and read what I could about it. I took one of the short drop pieces and created a "cheater tube" of the same angle the final bars would be, and I used that to layout a full size template using chalk on the garage floor. I layed everything out, took some notes on everything. then I walked away for the night.

the next day I went back out, and did the process all over again, and I doubled checked my numbers, and went over it all again in my head, and I again went back to the truck and re-verfied all my measurements, and compared to what I had layed out for the bends. after i was satisfied, I cut the tube to needed length, and placed it in the bender.






Committed now..



First bar bent, two more to go.



They all turned out pretty close, something I noticed the differences in but once it is finished I hoped would be something that would not be noticed by anyone else.

I needed to cut the bars down to final height, and cut the ends so they could sit properly on the brackets.





I used a paper template when making the angled cut.





That was easy enough, but it was just the first one, and there are 3 that have to match in order in order to keep everything level, so the roof top tent can sit properly on the bars

 

With each bed bar needing to be the same It took me a bit of time to get right. along with some creative clamping, and lots of checking with a level and and a straight edge.







Once again Not perfect, but it is close enough to work, long as nothing warps during welding.

Since my welding table is small I ended up tacking everything up on the truck. and that required some precautionary steps to protect the paint and the electrical system.




A welding blanket was used to protect the truck from the heat. I was fairly confident that the combination of the composite bed, and and placing the ground clamp as close to the area being tack welded as possible, that the electrical would be protected. know the risk to your electrical system if you choose to weld on your vehicle.






once everything was tacked in place it was time to weld out the bars. Creative work positioning once again came into play.





Not the prettiest weld out there... but I know it is strong, and will work for my needs.

The Side panel mounting tabs where up next, something that took a few attempts to find a way to clamp everything into place.



The idea was to have the side panels flush with the outside of the tube. I was thinking that any longer items would sit better on the rack that way.



I used the biggest magnets I had to hold the panel flush with the tube. everything was double checked, and the welding blanket put into place, and a final check was done to ensure nothing moved.







once everything was tacked into place, the panels need to come off in order to remove the bars, and do the final welding.



The Tabs turned out even better than I thought. Even though they are something that will go unnoticed by most everyone, I still wanted them to have a bit of style to them. and still be lightweight and strong.

After painting, it was time to reinstall the bed bars.

 

Can't forget the reason for the bed rack...

 

Dang that turned out awesome!

 

Great job

 

Thanks

It was a project that took a while to complete.. to this stage. Still have an addition to the rack that needs to be made, it was what I am calling "Phase 2"

 

Very nice. Thanks for posting your goofs along with your successes. Seeing those really helps others not make the same mistake.

 

Very cool!

 

Nice!!

 

I swear to God, some of you members make me look like a bum.

Here you are:

Ok, now I have a design, but I lacked the equipment to build it as designed, and it would involve skills I had yet to acquire

Here I am:

All my bowls are dirty....I wonder if pouring milk into the cereal bag is frowned upon?

Either way, looks fuckin great!!

 

I love that design. Wish I had it on my truck.

 

Turned out awesome. Great job.

 

Well.. I do have a design and the tools. So that can be arranged

 

Idk if u know this, but u just opened a huge fan of worms lol.

 

Well... the backstory on the design.

I had just broken a tooth at the gum line and I was waiting on the a surgical appointment. For the extraction. I was in a lot of pain even with the Vicodin and not really wanting to sleep since I was bit worried I would knock the tooth out and chock on it

So I stayed up a couple days straight and taught myself enough cad to design the rack

 

Haha, that would be great if I didn't already have one. Maybe in the future!

 

Badass man! Great job and nice looking welds especially for not playing the fab card for years

 

Rough draft of a 3rd brake light housing that is designed to mount to the rear bed bar. It will use the same rock lights I used on the truck. This version is designed to be mounted with stainless Zip Ties. I may work up a version with a Clamping system .


The Idea is this project will give a chance to learn a few new skills, and to increase my 3d Modeling skills. I plan on 3d printing the main body, and the lens will be vacuum cast in resin.