How to Build a Headache Rack

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Bulkhead (Headache rack) A strong wall-like structure placed at the front of a flatbed trailer (or on the rear of the tractor) used to protect the driver against shifting cargo during a front-end collision. A bulkhead may also refer to any separator within a dry or liquid trailer (also called a baffle for liquid trailers) used to partition the load.

Building a headache rack is not an extremely hard task and is relatively cheap. All you need is 25 feet (7.6 m) of 1 1 ⁄ 2 inch (3.8 cm) square tubing, 2 feet (0.6 m) of 1/4 x 1 1/2 inch strip of metal, a welder, and a chop saw.

Steps

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    Take and check how it fits on the pickup truck.
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    If there's no slider window, go 1/3 of the way in from each side.
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    Take the other two pieces, center, and tack them running with the cab.
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      Tips

      • Take your time, use common sense, and don't worry if pieces don't fit. Try make larger pieces and go a little smaller each time until they fit.
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      References

      1. ↑ https://www.youtube.com/watch?v=EYNqFAXuLUw
      2. ↑ https://www.youtube.com/watch?v=YckUDiyFXcI
      3. ↑ https://www.youtube.com/watch?v=0ZaCos6N40s
      4. https://www.youtube.com/watch?v=JaMgNqgefCA
      5. https://www.youtube.com/watch?v=OgL3lufUrSI

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