Roof Rack Headache Rack

These plans will help you make a simple wooden headache rack that mounts to your truck's roof rack. The plastic shroud on the edge of the cab of my truck is too weak to lean even a single 2x4. I needed something to allow me to haul several long items securely without sticking out the back. This rack mounted headache rack can easily be removed or modified to suit other needs. You'll want to measure and adapt these instructions to fit your truck and rack.

• 1x -universal cargo rack u-bolt set (model 92509 or similar)
• 2x - 2"x4" boards approx 3ft long
• 2x - 5/8"x4" boards approx 2.5ft long
• 1x - 2"x6" board approx 2.5ft long
• 8x - 1-1/4" outdoor screws
• 6x - 3" outdoor screws
• Wood glue as needed

1. Measure from the front of your roof rack to about 6 inches past the back of the cab. This is approx 3 feet. Its ok if the 2x4s are a bit long as this will provide side-to-side stability for the load.
2. Cut an upward 45 degree angle on each end. This will be the front of the rack.

1. Adjust and tighten the crossbars of the rack on your truck.
2. Place a 2x4 on the crossbars of the rack of your truck.
3. Mark the center of the crossbars on the 2x4.
4. Transfer this mark to the other 2x4.
5. Draw the shape of the end of the 5/8x4 using the center marks as the center of the shapes.
6. Using a jigsaw or chisel and hammer, notch out each of the 5/8x4. Use the 5/8x4 board to ensure flush.

1. Measure on the crossbars of your truck's rack the length across.
2. Cut the 5/8x4 boards (approx 2.5 feet)
3. Fit the 5/8x4 in the notches of the 2x4
4. Predrill the screw holes to prevent splitting.
5. Using 2 outdoor 1-1/4inch screws per end, attach the 5/8x4 to the 2x4.
6. Use wood glue as needed

1. Measure the distance between the 2x4s and cut the 2x6 so it will fit in between.
2. Use 3 of the 3inch outdoor screws per side to attach the 2x6 at the approx angle needed for your truck/rack. Do not tighten fully, predrill screw holes as needed
3. Put the rack on the truck and clamp it to the rack to keep it still
4. Using a spare long 2x4, place it in the bed of the truck against the tailgate.
5. Carefully loosen the 3 screws so that you can adjust the angle of the 2x6.
6. Be sure the 2x6 is positioned so that the sample 2x4 doesn't touch the cab (or shroud) and that the angle is such that the sample board lays flat
7. Once all adjustments are made, tighten the 3 3inch screws on each side

1. The crossbars of your roof rack on the truck may be curved. This can be solved.
2. In the center of your wooden headache roof-rack, attach two U-bolts (knobs up) to the crossbars. Only tighten the knobs enough to keep them attached
3. Starting from the middle, slide each U-bolt to the edges, bending the board to match the curve, then tighten evenly. Repeat for each crossbar.
4. Add the sample 2x4 and use a ratchet strap on the floor cab-side hooks of your truck to ensure the load is secure
5. Make sure your load doesn't exceed the weight limit of your roof rack