The term “headache rack” is a bit of a misnomer. Properly constructed, the rack that mounts at the front of a pickup’s box and extends up, providing coverage to the back window of the pickup cab, prevents headaches, or decapitation, from cargo shifting forward in the box of the truck. Headache racks can be very utilitarian in construction or quite decorative. It is sometimes constructed to include a roll bar and mounts for off-road driving lights.
Decorative headache racks can be built of out of light metal material. Use heavy metal square tubing, 2 inch square with one eighth inch walls, for example, to give the appearance of substance for the rack. It will be easier to weld the cross members to this heavier metal frame.
Some decorative headache racks use cut metal work for the cross member. These specially cut pieces of sheet metal can depict hunting or western scenes. The interior of the headache rack should allow visibility to the rear through the rear window.
While looking nice when mounted on a pickup truck, this type of headache rack offers little protection to the driver and passenger of the truck and shouldn’t be used in situations where shifting loads can present a danger.
Pickup truck drivers who haul heavy cargo that can shift forward need a headache rack that will protect the cab and its occupants. Loads of pipe or logs can be deadly if they shift forward and crash through the back window of the cab into the passenger compartment. For trucks used to haul these types of materials, heavyweight materials and construction techniques are generally used.
The framework is often made of 2 inch square tubing with quarter inch walls. The interior of the framework can be filled with any number of materials depending on the look the owner desires and the strength needed in the headache rack. Common materials are open metal grill work, metal bars or metal pipe. Whatever material is selected it should allow visibility to the rear of the truck.
The welds used to assemble a utilitarian headache rack should be performed by a qualified welding technician.
Decorative headache racks are often bolted to the lip of the box behind the cab. Utilitarian headache racks require more substantial mounting and can include bolting an extended portion of the rack into the stake sockets in the pickup box.
