How to Build a Headache Rack

Last Updated: January 20, 2022 References

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

1
Cut the top of the crossbar to the length of the top of your cap or on a 1991 Ford cut at 58 inches (147.3 cm).^{[1]
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2
Cut two sides at 35 degrees at both ends going opposite directions at 23 inches (58.4 cm) in length.^{[2]
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3
Tack where the sides angle out. Take and check how it fits on the pickup truck.
4
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.
5
Tack and check once more.
6
Cut your 1 ¹⁄₂ inch (3.8 cm) x ¹⁄₄ inch (0.6 cm) flat strap into 4 x 6 inch pieces.
7
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.
8
Drill your hole in both rack bases and bed to line up and bolt.^{[3]
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