- Deciding how you intend to use the rack is the first step. If you want it for hauling ladders, the rack must be higher than the truck cab to allow long ladders to extend over the front of the cab. If the rack is to increase firewood hauling capacity, you want a rack built of heavy, strong material that can take a beating. Do you need a lot of tiedowns? Will you install the rack as a permanent part of the truck, or do you intend to remove it? Sketch the rack on paper.
- Measure the dimensions of the stake pockets on your truck bed. These are the rectangular metal pockets typically located at each corner and in the middle of the sides. These are the anchor points for your rack. They are generally smaller than a 2-by-4, so you'll probably have to rip wood down to the right dimensions. Don't use cheap or knotty wood for the rack. The knots greatly weaken the wood strength. Some small, tight knots are OK, but the fewer the better, especially on the support posts.
- Consider the stresses on a truck rack and reinforce accordingly. A truck rack will be vibrating, shifting and twisting. Wood has a natural ability to flex and absorb vibration. The weakness is in connecting the pieces of wood. On a rack such as for hauling wood, the multiple slats or plywood sidewalls offer plenty of strength. On an open ladder rack style you will have to cut triangular-shaped gussets to screw on the corners for extra stability.
- Consider how you will secure tiedowns, ropes, tarps, ladders, boats or whatever else you may need to secure. Don't forget to install cleats, D-rings, or bull-rings in strategic locations on the rack or the truck. And never drive with an unsecured rack. Always bolt or clamp the rack securely to the truck bed.
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