How Do You Build A Headache Rack?
• Cut the top of the cross bar to the length of the top of your cap or on a 1991 Ford cut at 58 inches. • Cut two sides at 35 degrees at both ends going opposite directions at 23 inches 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 1 1/2 inch x 1/4 inch 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.
