Here is a VERY rough draft of the headache rack im planning on building for my truck. Frame is 2 inch square tubing, internals "V"s are 2 inch flat stock spaced 2 inches apart so actual product wouldn't have so many as the picture. Light areas are appropriate sized flat stock to house the oval lights. It will have angles braces at the lower corners where it meets the bed, along with bed length rails all welded together to the rack. Let me know what y'all think? Too busy? Not a good idea? All feed back is appreciated.

 

Pretty much all louvered style headache racks are horizontal louvers for better vision. Not sure how the angled louvers will be. I'm thinking you will have vision issues.

 

Here is a better drawing..

 

Check your local salvage yards for some louvers from a cooling tower for your slats. Here is what I did with my bed, use some 2x3 x 3/16" angle for your bed cap:





This is what X-Metal Looks like:

 

Thats really close to what im lookin into doin except not the hand rail on the bed. I love the bent top rail to match the contour..how did you do it? What are cooling towers? I also found a metal surplus place down the road from my work. What part of CO you from?

 

I live in the NW Corner (Rangely). If your local fab shop has a roller they can roll your tubing to whatever radius you want, if not do what I did, make 3 equal marks on the top pce, use your chop saw and cut halfway into the metal tubing (this will tell it where to bend). Wrap a chain around the tubing use a jack to bend it to the desired angle. Weld up as needed. Cooling towers are used at various types of plants most have movable louvers to adjust temps. Some of the louvers have some nice rounded edge shapes to them.

 

I will have to check into those cooling tower louvers. What are they made of and how well do they take to welding? I like the bent top part idea..it will allow for the top brace to be a little lower and still have 3rd brake light visibilty

 

Some are metal some are AL which would require a bolt on design. Keep in mind some of these cooling towers are12' x 40' Long or bigger.

 

Holy cow thats big..