Bed rack build steel vs aluminum?

I’ve got a bed rack designed that I’d like to have a fabricator weld up for me.

The material will be either aluminum or steel 1.5” square tubing. Not sure on wall thickness yet.

Rack will be the same height as the cab of my truck, so fairly large.

Curious which material you’d recommend it be built out of? Are the weight savings worth having it made out of aluminum? Or will the added strength of steel be better for this kind of application? I see many companies out here using both...

Not planning an RTT but I’d like to have that option if it arises.

Thank you guys!

Ben

 

Aluminum can be lighter than steel for specific applications depending on the required load bearing requirements of the rack. You have not mentioned what you intend on hauling on top of the rack or what your maximum load rating for the rack is.

I will ALWAYS opt for weight saving aluminum construction if the design characteristics of the project are well within the yield strength of the aluminum. You can also design the rack in a way that the load bearing portions are made up using trusses of smaller dimension tubing (square or round), but that adds more welding and fab labor to the project, as well as additional material costs.

So, YOU need to decide whats more important. Weight savings or cost of the project.

You could also build a hybrid rack where the vertical posts that attach to the truck are steel for strength, and then fabricate brackets that allow you to attach 8020 type aluminum extrusions which would allow you to reconfigure the rack or even remove it (easier) when you don't want or need it in place.

The sky's the limit here, but since you DID say that you were entertaining 1.5" square tubing, my assumption is that your load bearing requirements are not that high. 1.5" .060 wall (steel) tubing is not that strong, and 1.5 x .120 is stronger, but both will bend in the middle of a 6 foot span rather easily if not braced in the middle somehow.

2 rows of 1.5" x .060 spaced 6" apart (vertically) and braced 2 or 3 times in a 6' span will be exceptionally strong, but now you have doubled your material cost, but more importantly, you have DEFINITELY doubled your labor cost, particularly if someone is TiG'ng this thing together, which is how I would do it.

Anyway, more info is needed to give you a better idea of how I would bid the job, or give you an idea of what I think is the right way to do it.

Can you share a rendering of your design so I can get an idea of what you are up to?

P.S. I weld my own stuff and have been fabricating for decades now, but do not do it for a living. I can at least share my experience with you.

 

Thank you for the reply,

I keep going back and forth on this thing. Mostly because I cam having trouble finding anyone that is willing to weld on aluminum in my area.

If aluminum was used I would be using 1.5" square tubing, along with 1.5" x 3" tubing, both with a 0.125" wall of the 6105-T5 alloy.

I don't plan on having a large load on top on this ever, but I'd like it to be strong as possible in the case I someday need it to hold up.

The design I've drawn up doesn't have a center brace, yet. If I go this route I may try to incorporate a removable middle brace.



Thanks for the thoughts.

Also, I do like the hybrid idea, steel support with an 80/20 aluminum basket. I had everything drawn up for that at one point and may visit the idea since I can't find a welder to weld this currently.


Ben

 

Yeah so if you look at the 8020.net website here: https://8020.net/gallery

And then click on the DIY link in the gallery, scroll down a bit and there are 2 guys that have built racks with 8020. One is a bike rack and the other is heavier duty.
The cool thing about it being modular is that you can take it down (off) or reconfigure it as needs change. Welding one up almost ALWAYS results in those "oh shit" moments where once it's done and you start using it, you realize that you should have done something slightly different and now you are stuck. Or you have to take it back to the fabricator and have him modify it for you. $$$

Maybe put some thought into the base of the rack being steel that you can have fab'd up to your liking and then configure the top section(s) out of 8020 and use stainless hardware to keep it all alive through the seasons. Maybe get the base powder coated when it is done to stave off galvanic corrosion between the aluminum and steel and run with it. Or just go with all 8020 and have the option of buying new pieces as need dictates.

Here is the pic from 8020.net

 

I just ordered the Cali raised rack because it has the steel base and 8020 extrusion. I like the fact that it's modular and I can take off the cross bars if i have something tall to haul. I think you've got the right idea OP. 8020 is fun stuff to play around with.

 

I had not seen that yet, I'd much rather use 8020 for the reasons you've mentioned. Looks like I need to play around with it some more. There are tons of ways to configure one going with the 8020, and plenty of ways to mount things to it.

Thanks,

Ben

 

I'm going with aluminum from SOS Concepts for over my Softopper for my RTT

 

That's a stock pic from their site, but this is my truck it will be going on.

 

Checked into these, they're very nice. Spendy but nice!

Ben

 

Gotta pay for quality and workmanship

 

You're not wrong, and as far as bed racks go they're right in the middle of the pack with pricing. But if I can save a bit of moneies by doing it myself I'll go that route.

Ben

 

Damn Skippy

 

What is an "RTT" ?

 

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