1994-2020 Dodge 2500/3500 Digital Headache Rack Kit


This Digital Kit inlcudes everything you need to complete our weld-yourself headache rack for 1994-2020 Dodge 2500/3500 SRW and Dually Pickups. The kit is designed to be used in combination with our start to finish video tutorial.

What’s Included:

  1. Easy-to-Use Blueprint – downlaodable upon purchase. See photo 1 or scroll down to preview.
  2. .DXF Cut Files for all needed machine made parts – downloadable upon purchase. Includes CAD drawings for both types of gussets (regular and toolbox) and light brackets.
  3. Access to the start to finish video tutorial.

Adding marker lights and/or strip tail/stop/turn lights are optional. Product links to purchase these items are available to purchase directly from the video tutorial page.

SKU: chevy-premium-headache-rack-kit-1-1-1 Categories: , ,
Double Diamond Headache Rack Kits

What Experience and Tools are Required to Build My Kit?

Equipment Required:

  • Standard Protective Equipment (Ear Plugs, Safety glasses, Welding Helmet, Welding Gloves, Welding Coat)
  • Work Table
  • Welder – capable of welding 3/16” plate
  • Bandsaw capable of cutting 2.5” square tubing (If you don’t have a bandsaw, you can get your pieces cut at a local welding shop)
  • Angle Grinder
  • Tape Measure
  • Vice grips OR C-clamps – at least two, four preferred
  • Square
  • Hand Drill OR Drill Press
  • ¼” Drill Bit
  • ¾” Drill Bit (only needed if adding marker lights)
  • Type 27 Flapper Disk Grinding Wheels
  • Grinder Cutting Wheel OR Plasma Cutter OR Cutting Torch

Experienced Required:

  • Beginning to Intermediate Welding Experience
  • General Knowledge of using a bandsaw (includes cutting angles) If you don’t have a bandsaw, you can get all your pieces cut at a local welding shop.
  • General Shop Tool Knowledge (how to use hand drill, grinder, etc.)

No Experience or Tools? No Problem. Give your local welding shop a copy of the blueprint and video access and they will easily be able to complete the project.

What's Included

1) Easy-to-Use Blueprints

These aren’t the jargon-filled standard blueprints, they’re made for everyone to understand. Blueprints Include a detailed material list and diagrams covering lengths and angles to cut all pieces.

What's Included

2) .DXF Cut Files

Includes CAD .dxf files for all needed parts including standard gussets, toolbox gussets, and light brackts.

Preview Our Double Diamond Kit Blueprints

Frequently Asked Questions

This course is easy to follow, but what if I have a question? Will there be support available?

Absolutely. We make sure every customer is able to fully complete their rack. All purchasers will have full access to email and phone support (with a real human) ensuring any and all questions are answered.

How much is this going to cost to build the finished product, all things considered?

Digital Kit – $79

*Steel you will need to purchase – $90-$110

*Finish (Paint/Powder Coat) – $10 – $150 

Total: $199 – $369

Add Marker Lights & wiring (6): +$35

Add Strip Tail/Stop/Turn Lights & wiring: +$35

Compare to Protech Premade Rack: MSRP $475-$750

Compare to Highway Products Premade Rack: MSRP $599+

*Price subject to your area’s steel retailer and powder coat supplier*

Does this product fit with a cross body toolbox?

Yes. Simply choose the toolbox option at checkout for a specialty gusset to fit with most cross body tool boxes. The maximum overall outer width of the toolbox that can be accommodated is 73.75″ outer width.

How long will it take to build?

An experienced fabricator can get this project done in 6 hours, whereas a beginner might need a full day.

Weld-it-Yourself Headache Rack Kits

Every kit includes easy-to-follow blueprints, machine made parts shipped to your door, and full access to our step-by-step video course.

Additional information

Gusset Type

Regular, Toolbox


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