How to Choose a Headache Rack

The one accessory that’s always got your back.

Words by Perry Mack

We were recently loading split logs into the bed of a buddy’s truck. Without even looking, our movements were automated - lift, throw, repeat. At one point we both threw at the same time, which is why we don’t know who broke the rear window of the cab.

Headache racks (aka cab guards) are one of the few functional aftermarket accessories that have many unique styles. If you drive a popular truck like an F-150 - with as many as 50 in any given neighbourhood - each may have a different rack, which is great as you can still find one to personalize your truck. That’s the good news. The bad news is trying to decide which one suits your style and meets your needs.

Why buy one? 

The first and foremost reason is safety. If you happen to have loose gear in the bed and either brake hard or hit something head-on, it stops cargo from flying through the rear window and nailing the driver and passengers in the cab. Should you want to securely mount a toolbox, you can sometimes drill and bolt it to the rack rather than your truck bed. They are also a great place to attach lights, tie-down mounts, tool holders and more. In the case of a louvered rack, they can also provide some shade for the cab.

The first choice is whether to go with a universal or custom fitment. Universal racks (often made offshore) are cheaper as the construction cost benefits from economies of scale. Manufacturing 10,000 identical guards is a lot cheaper than 100 guards for 100 different models, especially since the guards often need to be redesigned for new model years. 

Universal guards are often trickier to install since they come with parts to ‘sort of fit’ numerous different trucks. Instructions are typically unclear, customer service the same, so your install skills need to be above average.

What’s Going in the Truck Bed?

Trucks beds can be used to haul larger materials like lumber or firewood or smaller materials like gravel and rebar. Weather Guard builds safety headache racks from steel mesh (as well as other materials) to offer protection from finer materials. However, you do lose some visibility so only go this route if you don’t think you’ll need it. Many of their racks are standard (universal) and you can order the mounting kit specific to your vehicle. www.weatherguard.com

Made from What?

You can choose either aluminum or steel. If you have ever needed to make this choice before, you know that steel is stronger, more rigid, and costs less. Aluminum is lighter and corrosion-resistant. Choose aluminum if you’re planning to install, remove and store repeatedly. Many of us use overhead storage and launching steel parts overhead can be hard. 

Remember that most of the aluminum is welded (and welded well) rather than bolted together. Since aluminum is soft, bolted-together crossbars can loosen and deform over time. Also, use stainless steel bolts and washers during assembly. Steel and aluminum are like oil and water – they don’t mix well. It’s called galvanic corrosion, but you can use them together as long as you put insulating material between them.

If you prefer aluminum and rail guards, LEDs, a toolbox and/or ladder rack are for you, look at the options from Westcan Manufacturing based in Chilliwack, BC. With so many choices, the parts come a la carte so order carefully and get the right install kits to go with your rack. www.westcanmanufacturing.com.

Rack Plus What?

In the event you already own a tonneau cover, start your search with the same manufacturer as they probably build compatible systems. Many tonneaus encroach on the area that the cab guard uses to mount to the bed. Other tonneau builders clamp their covers to the inside rail of the truck bed, so the stake pockets are exposed. 

This style of tonneau works with more cab guards, although you may have to purchase a tonneau cover adapter like those supplied by BackRack for their cab guards. BackRack is a good option if you want a steel rack as there are many styles including open, safety, louvered, half safety, half-louvered, round bar as well as square, and three-light cab guards for added visibility and personalization. 

The company also manufactures several accessories for their racks, many of which could be essential to your needs - from tool holders and antenna mounts to ladder and toolbox brackets. As a bonus, they’re made in Oakville, Ontario. 

If you prefer aluminum, an aggressive-looking extruded aluminum rack that has lots of accessories is the AdvantEDGE Headache Rack from Aries Automotive. It’s a burly, modern-looking unit that comes in either a chrome or black carbide powder coating. Jeep owners will recognize the name as a manufacturer of tough-as-nails off-road accessories. www.ariesautomotive.com

It’s also important to consider the load rating of these racks. If you’re thinking about adding a rooftop tent or other load heavier than a ladder, and utilizing your headache rack as the front portion of your ladder rack, check with the manufacturer as most headache racks are not designed to carry this type of load and the load rating is typically not an advertised spec.

There are a few cons to headache racks. Depending on which one you choose, you could lose some visibility out the back window, it could interfere with a rear-facing bed cam, and if you accessorize with light bars or tool holders, you often lose the ability to use it as a ladder rack.

However, the pros far outweigh the cons and adding a headache rack to your truck is never a bad idea. It should probably be called an ‘anti-headache’ rack.