🪜 Custom Ladder Rack installed on 2022 Maverick [1k lbs capacity]

[Old Fart]

Just installed a ladder rack on my XLT now it’s a work truck! Lots of modification needed, welding cutting and grinding to get it to fit.

Ford I wish the bed rails were more friendly to truck bed accessories. Only the expensive Yakima racks fit out the box that I know of. Also wish rails on top of the cab were installed to make it easy to add too. It’s a truck and we want to use it to carry stuff otherwise we would be in a sedan! Also just wanna say I absolutely love my Maverick except for that.

Updated 10/26 with more photos and details:

This is how we got it to fit!! -- I bought a universal rack for my truck rated to carry 1000lbs. We needed to cut and weld back together the clamps to make them fit. We had to shorten the height of the rack by sawing off about 6” from each of the vertical pieces then drilled new holes. This part was difficult as the parts are not straight for measuring or clamping in the drill press. We welded the top side pieces also as the verticals closest to the cab went right over the seem which were supposed to have a bolted clamp holding them together.

Then it was a case of bolting it all together. It took about 6 hours. Feels pretty solid.

The ladder pic is with a 24’ ladder. Getting my 28’ on it soon.

Good job, I love a challenge, can carry an 16 foot ladder inside my wagon now glad to know this is possible.

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[mcarneybsa]

Thank you so much for this post! I've been day dreaming of how I would make this work and now I don't have to!

Personally I think this was "hard mode" for making a custom rack. Anyone can use Unistrut or 8020 profile to build the same thing and not need to weld, or even drill.

I just priced what it would take to build a similar rack from 15-series 8020. The only difference would be that my design purposefully doesn't go as far over the cab (only 2 ft). With all of the profile and connectors it's $550. The only tool you need to put it together is a couple of wrenches. With Unistrut you could do it for even less (~ $300-400), but I like the look of 8020. Either of those materials allows you to build it, modify it, add to it, change it, etc., with just a couple of wrenches. So if it turns out that I really do need to have it extend farther over the cab, I can just order two new pieces and swap them out. Or if I want to change the spacing on the uprights I can just unbolt, slide them around, and re-bolt. Lastly, the 8020 is aluminum - it will weigh way less than a steel rack like this and be more corrosion resistant. For a 300lb load, the 8020 extending 24" over the cab, I'll see a total of 7mm of deflection, and that's with all 300lb on the very end of a single arm.

 

[Isoruko]

Very nice to see a job well done, and a good look and functionality added!
I have the exact truck on order, just hybrid, and planned on doing this exact modification once it finally comes in!
I work in a machine shop, and have access to anything I could need to make it happen, or to make what mcarnybsa is describing, but I'll be taking the same route as you.
Cost/vs functionality. I want the extra length for kayaks and the occasional lumber and ladder, and don't need to spend extra for aluminum. Plus I think 80/20 or unistrut will look much tackier that this ordinary yet professional looking rack. To each their own though. I'll just load up the trailer or the f350 if weight or space is an issue

 

[KGillies]

Thanks for the Info, I sometimes need to haul 12 or 14 foot lumber and was looking for a solution. Do you think this rack can be used with a tonneau cover?

no his clamping system won't work with tonneau. See https://realtruck.com/p/elevate-rack-system/trx-1118328/

 

[Mav2Scamp]

Just installed a ladder rack on my XLT now it’s a work truck! Lots of modification needed, welding cutting and grinding to get it to fit.

Ford I wish the bed rails were more friendly to truck bed accessories. Only the expensive Yakima racks fit out the box that I know of. Also wish rails on top of the cab were installed to make it easy to add too. It’s a truck and we want to use it to carry stuff otherwise we would be in a sedan! Also just wanna say I absolutely love my Maverick except for that.

Updated 10/26 with more photos and details:

This is how we got it to fit!! -- I bought a universal rack for my truck rated to carry 1000lbs. We needed to cut and weld back together the clamps to make them fit. We had to shorten the height of the rack by sawing off about 6” from each of the vertical pieces then drilled new holes. This part was difficult as the parts are not straight for measuring or clamping in the drill press. We welded the top side pieces also as the verticals closest to the cab went right over the seem which were supposed to have a bolted clamp holding them together.

Then it was a case of bolting it all together. It took about 6 hours. Feels pretty solid.

The ladder pic is with a 24’ ladder. Getting my 28’ on it soon.

Wow that’s nice!! Man you are really creative.

 

[Dandylion]

Personally I think this was "hard mode" for making a custom rack. Anyone can use Unistrut or 8020 profile to build the same thing and not need to weld, or even drill.

I just priced what it would take to build a similar rack from 15-series 8020. The only difference would be that my design purposefully doesn't go as far over the cab (only 2 ft). With all of the profile and connectors it's $550. The only tool you need to put it together is a couple of wrenches. With Unistrut you could do it for even less (~ $300-400), but I like the look of 8020. Either of those materials allows you to build it, modify it, add to it, change it, etc., with just a couple of wrenches. So if it turns out that I really do need to have it extend farther over the cab, I can just order two new pieces and swap them out. Or if I want to change the spacing on the uprights I can just unbolt, slide them around, and re-bolt. Lastly, the 8020 is aluminum - it will weigh way less than a steel rack like this and be more corrosion resistant. For a 300lb load, the 8020 extending 24" over the cab, I'll see a total of 7mm of deflection, and that's with all 300lb on the very end of a single arm.

Would love to see pics of your rack, too.

 

[KenC]

Personally I think this was "hard mode" for making a custom rack. Anyone can use Unistrut or 8020 profile to build the same thing and not need to weld, or even drill.

I just priced what it would take to build a similar rack from 15-series 8020. The only difference would be that my design purposefully doesn't go as far over the cab (only 2 ft). With all of the profile and connectors it's $550. The only tool you need to put it together is a couple of wrenches. With Unistrut you could do it for even less (~ $300-400), but I like the look of 8020. Either of those materials allows you to build it, modify it, add to it, change it, etc., with just a couple of wrenches. So if it turns out that I really do need to have it extend farther over the cab, I can just order two new pieces and swap them out. Or if I want to change the spacing on the uprights I can just unbolt, slide them around, and re-bolt. Lastly, the 8020 is aluminum - it will weigh way less than a steel rack like this and be more corrosion resistant. For a 300lb load, the 8020 extending 24" over the cab, I'll see a total of 7mm of deflection, and that's with all 300lb on the very end of a single arm.

cool story, bro.

 

[mcarneybsa]

Would love to see pics of your rack, too.

I plan on doing a video of the build. My production date is Monday, so it will still be a few weeks.

 

[mcarneybsa]

cool story, bro.

cool comment, bro.

 

[tmiller]

Personally I think this was "hard mode" for making a custom rack. Anyone can use Unistrut or 8020 profile to build the same thing and not need to weld, or even drill.

I just priced what it would take to build a similar rack from 15-series 8020. The only difference would be that my design purposefully doesn't go as far over the cab (only 2 ft). With all of the profile and connectors it's $550. The only tool you need to put it together is a couple of wrenches. With Unistrut you could do it for even less (~ $300-400), but I like the look of 8020. Either of those materials allows you to build it, modify it, add to it, change it, etc., with just a couple of wrenches. So if it turns out that I really do need to have it extend farther over the cab, I can just order two new pieces and swap them out. Or if I want to change the spacing on the uprights I can just unbolt, slide them around, and re-bolt. Lastly, the 8020 is aluminum - it will weigh way less than a steel rack like this and be more corrosion resistant. For a 300lb load, the 8020 extending 24" over the cab, I'll see a total of 7mm of deflection, and that's with all 300lb on the very end of a single arm.

Care to share your design, looked up 8020 and it looks like a good option?

 

[Mika]

I think that really looks sharp and very professional. What rack did you start with to modify?

I was in a hurry as I needed the 28’ ladder for a job the next day so just got one off Craigslist. No info with it just a jiant jigsaw puzzle of a rack.

 

[mcarneybsa]

Care to share your design, looked up 8020 and it looks like a good option?

I don't know how to use CAD software (I probably should learn it) but I can use graph paper and a straight edge. The item details are in my chicken scratch, but the important bits should be readable.



All-in it will be about $550. I'm still toying with a few options for feet attachments and if I want to rig it with a tonneau cover or not. I didn't dig too deep to find angled connectors like the xtrusion-overland rack uses. If I can find some I will use them, otherwise I'll stick with vertical uprights.

 

[tmiller]

I don't know how to use CAD software (I probably should learn it) but I can use graph paper and a straight edge. The item details are in my chicken scratch, but the important bits should be readable.



All-in it will be about $550. I'm still toying with a few options for feet attachments and if I want to rig it with a tonneau cover or not. I didn't dig too deep to find angled connectors like the xtrusion-overland rack uses. If I can find some I will use them, otherwise I'll stick with vertical uprights.

Thanks! Now I just need a truck....

 

[mcarneybsa]

Thanks! Now I just need a truck....

same. Mine went into production late last week with today listed as the blend day, but it sounds like the factory is on a pause this week, so we'll see if it's just for new construction starts or not.

 

[jonathan1994]

I'd be fine with building one that bolts to the top of the bed rails outside the trifold cover.
Is there a place to drill holes that leaves access for nuts beneath?

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