Cheap DIY bed rack that works with tonneau cover

[Blacksmith]

I've been looking for the cheap bed rack which will work with my Truxedo pro x15 for the last two years. And didn't find anything.
Truxedo cs is the most popular option here, but still 900 USD +.
The other racks doesn't work with the cover.
So I found this simple solution on the jeepgladiator forum and decided to adopt it for my Mav.
https://www.jeepgladiatorforum.com/...t-slot-rack-for-bak-revolver-x4s.59111/page-4
Bought 1.5" t slot beams, brackets, fasteners, can of loctite from mcmaster and pair of cheap cross beams from Amazon.
https://www.amazon.com/gp/aw/d/B09NZPDZZ1?psc=1&ref=ppx_pop_mob_b_asin_title
It took less than an hour to assemble it and install on my truck.
Here is the result.
It's sturdy and my kayak will definitely fit there.
I didn't feel any excessive noise on the highway and don't see any drop in fuel consumption. At least so far

PS: Sorry for the duplicated last photo. Looks like delete button doesnt work on this forum

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[Zomdos]

This is fantastic thank you for sharing!

How much space is in the back between the cover and the tailgate? Are you still mostly water tight?

 

[Blacksmith]

its zero gap there. The bed is still water tight

 

[TheSEARCH]

I've been looking for the cheap bed rack which will work with my Truxedo pro x15 for the last two years. And didn't find anything.
Truxedo cs is the most popular option here, but still 900 USD +.
The other racks doesn't work with the cover.
So I found this simple solution on the jeepgladiator forum and decided to adopt it for my Mav.
https://www.jeepgladiatorforum.com/...t-slot-rack-for-bak-revolver-x4s.59111/page-4
Bought 1.5" t slot beams, brackets, fasteners, can of loctite from mcmaster and pair of cheap cross beams from Amazon.
https://www.amazon.com/gp/aw/d/B09NZPDZZ1?psc=1&ref=ppx_pop_mob_b_asin_title
It took less than an hour to assemble it and install on my truck.
Here is the result.
It's sturdy and my kayak will definitely fit there.
I didn't feel any excessive noise on the highway and don't see any drop in fuel consumption. At least so far

PS: Sorry for the duplicated last photo. Looks like delete button doesnt work on this forum

Great setup. I used yakima clip on bars on roof BUT I would like to do at least one cross bar in the back so I can load from the rear rather than the side. In have a few questions I hope you don't mind

.
So I would start with rails 50 inch rails only , correct?

https://realtruck.com/p/elevate-rack-system/v/ford/maverick/2023/


. I want to load from the rear of truck kayaks like you.. 16' foot and 17' 2" kayaks. (Valley Avocet, Tiderace Pace Tour 17)


So I need TWO of these per cross bar BUT not sure on length. Yours looked like perfect length for proper height

to clear roof. , What length did you use?

https://www.tnutz.com/product/ex-1515-black/


So I would need Brackets 6 per cross bar

https://www.tnutz.com/product/cb-015-k-black/


Nuts that wont spin inside the slots? Is this what you used. Plus 5/16 bolts not sure what Length??
.Is that what you used below?

https://www.amazon.com/gp/product/B07TK14BW3/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1

 

[Blacksmith]

Great setup. I used yakima clip on bars on roof BUT I would like to do at least one cross bar in the back so I can load from the rear rather than the side. In have a few questions I hope you don't mind

.
So I would start with rails 50 inch rails only , correct?

https://realtruck.com/p/elevate-rack-system/v/ford/maverick/2023/


. I want to load from the rear of truck kayaks like you.. 16' foot and 17' 2" kayaks. (Valley Avocet, Tiderace Pace Tour 17)


So I need TWO of these per cross bar BUT not sure on length. Yours looked like perfect length for proper height

to clear roof. , What length did you use?

https://www.tnutz.com/product/ex-1515-black/


So I would need Brackets 6 per cross bar

https://www.tnutz.com/product/cb-015-k-black/


Nuts that wont spin inside the slots? Is this what you used. Plus 5/16 bolts not sure what Length??
.Is that what you used below?

https://www.amazon.com/gp/product/B07TK14BW3/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1

I used four hollow aluminum t-slot rails 2 feet long.
Then on the cross beams itself. They are actually flat on the bottom. So its just a direct contact between two flat surfaces
As for the gussets, I used 12 aluminum gussets 47065T798 from McMaster. 4 T-slot fasteners are included with each gusset. Thats what I used there.
Here is the link to traditional t-slot fastener
mcmaster.com/47065T905/
In general this setup is really simple.
I didnt modify any parts, just bolted everything together

 

[TheSEARCH]

I used four hollow aluminum t-slot rails 2 feet long.
Then on the cross beams itself. They are actually flat on the bottom. So its just a direct contact between two flat surfaces
As for the gussets, I used 12

from McMaster. 4 T-slot fasteners are included with each gusset. Thats what I used there.
Here is the link to traditional t-slot fastener
mcmaster.com/47065T905/
In general this setup is really simple.
I didnt modify any parts, just bolted everything together

So you used Mcmaster.com for everything ?

The link you gave us for those washer but they are 1/4 inch. You used 1/4 inch? Seems small?

So these upright 1.5 inch hollow t-slot rails at 2 feet long each?
https://www.mcmaster.com/products/t...w/t-slotted-framing-component~rail/?s=t-slots


And these are the gussets
https://www.mcmaster.com/47065T798/

Now if I get the hollow Tslot bars and the gussets which come with washer and bolts? Plus mcmaster.com/47065T905/
Do I need anything else ?

Sorry for all the questions BUT this is all new to me making things like this .

 

[Blacksmith]

So you used Mcmaster.com for everything ?

The link you gave us for those washer but they are 1/4 inch. You used 1/4 inch? Seems small?

So these upright 1.5 inch hollow t-slot rails at 2 feet long each?
https://www.mcmaster.com/products/t...w/t-slotted-framing-component~rail/?s=t-slots


And these are the gussets
https://www.mcmaster.com/47065T798/

Now if I get the hollow Tslot bars and the gussets which come with washer and bolts? Plus mcmaster.com/47065T905/
Do I need anything else ?

Sorry for all the questions BUT this is all new to me making things like this .

I included this link to t-slit fasteners just for reference. You don't need to buy it. As I said each gusset comes with 4 fasteners. So you need 2 feet rails, 12 gussets and 2 cross beams from Amazon. That's it.
Oh, by the way, don't forget to buy small bottle of loctite to fix all these fasteners in place

 

[TheSEARCH]

I included this link to t-slit fasteners just for reference. You don't need to buy it. As I said each gusset comes with 4 fasteners. So you need 2 feet rails, 12 gussets and 2 cross beams from Amazon. That's it.
Oh, by the way, don't forget to buy small bottle of loctite to fix all these fasteners in place

Thank you very much for your help. My kayak loading will be faster and easier next summer for sure.

 

[NatePabrant]

I'm not understanding how you have a water tight tonneau cover but also rails at the edge.

 

[Blacksmith]

I'm not understanding how you have a water tight tonneau cover but also rails at the edge.

It's definitely possible with the right cover. I'm using Truxedo pro X15 soft rolup cover on my orange truck and Rough Country hard tri fold on my blue one. Both trucks have rails.
Basically you have to install rails first and then rails which comes with the cover above it and clamp in place with 6 clamps. I'll try to post picture tomorrow. It's just dark and raining outside

 

[NatePabrant]

It's definitely possible with the right cover. I'm using Truxedo pro X15 soft rolup cover on my orange truck and Rough Country hard tri fold on my blue one. Both trucks have rails

I have the Ford hard tri-fold (I'm pretty sure it's rebranded but I can't remember what the other forums users said it was).
Do you know if it can have rails?

 

[Blacksmith]

I think I saw a good table somewhere on this forum with a list of covers which work with the t rails. I'll try to find it

 

[Blacksmith]

Here you go.
https://www.mavericktruckclub.com/forum/threads/bed-rack-that-works-with-hard-folding-tonneau.21652/
This is pretty old post but still good source of information

 

[TheSEARCH]

You will need just the rails for 239.99 assuming your cover works with them

https://realtruck.com/p/elevate-rack-system/v/ford/maverick/2023/

Here is video on maverick
https://realtruck.com/p/elevate-rack-system/v/ford/maverick/2023/

 

[Hammer]

I have the Ford hard tri-fold (I'm pretty sure it's rebranded but I can't remember what the other forums users said it was).
Do you know if it can have rails?

Ford hard tri-fold is the rebranded BakFlip G2

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