Building a headache rack with rotating light bar

I love lights above the cab but hated the idea of the clearance issues. I already have enough trouble fitting into parking garages and under low hanging trees. A few years ago I thought about building a rack with a rotating light bar, but just never seemed to have the time to build it. I also wanted a rotating light bar because in the up position I could have all four lights facing forward lighting up the road and in the stow position, have all four lights facing rearward to light things up. With the help of my dad who has all the right tools like plasma cutter and heavy duty welder, we built it. With a 20' piece of 1/8" wall 2x2 square stock and a few pieces of various scrap plate steel laying around we got to work.

I wanted a low profile headache rack that followed the body lines of my truck. I also wanted the lower crossbar at the right height to prevent the Grizzly quad from tap-tap-tapping on my rear window. Futher, the rack had to sit back from the cab because during extreme flex, there isn't a whole lot of room between the bed and cab.

We started by building two base plates to fit into the front stake pockets. This required a bit of creative effort with pieces of angle iron and a whole lot of measuring. That was pretty much the hardest part of the project as everything else was just straightforward cutting and welding.

I decided to go with four KC HiLights 57 series rectangular lights. Their 100W Halogen H3 bulbs produce 167,000 candlepower a piece. I have installed two Hella 500s behind the grill and I'll say that KC has the better wiring kits. So much more straighforward and makes for a clean install because all the pieces are pre-wired. You literally just run the wiring and plug things in. This install was pretty easy because I already have a battery in the bed for my 1500W inverter.

Click on a pic for higher resolution images.




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There are 4 comments so far.

September 12, 2012, 11:01 pm (MST) - Anonymous said:
The albiity to think like that is always a joy to behold

June 2, 2013, 10:04 pm (MST) - RC Anderson said:
I noticed that you changed the mountings for your scuba tanks in these photos. Where did you find those mounts, I have been looking for them but I can not remember what they are called.

August 19, 2015, 1:53 am (MST) - MZvzZtpv said:
This is getting a bit more svjtecbiue, but I much prefer the Zune Marketplace. The interface is colorful, has more flair, and some cool features like Mixview' that let you quickly see related albums, songs, or other users related to what you're listening to. Clicking on one of those will center on that item, and another set of neighbors will come into view, allowing you to navigate around exploring by similar artists, songs, or users. Speaking of users, the Zune Social is also great fun, letting you find others with shared tastes and becoming friends with them. You then can listen to a playlist created based on an amalgamation of what all your friends are listening to, which is also enjoyable. Those concerned with privacy will be relieved to know you can prevent the public from seeing your personal listening habits if you so choose.

November 11, 2015, 6:34 pm (MST) - n4ar9zCdWz said:
I've learned quite a few imtrapont things by means of your post. I will also like to say that there can be situation in which you will make application for a loan and don't need a cosigner such as a Federal government Student Aid Loan. However, if you are getting financing through a conventional financier then you need to be able to have a cosigner ready to enable you to. The lenders are going to base their decision on a few aspects but the most significant will be your credit ratings. There are some financial institutions that will additionally look at your job history and make up your mind based on that but in many instances it will depend on your score.


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