How To Make A Truck Shell Storage Rack

Materials Needed

Before starting the project, it is important to gather all the necessary materials. Here is a list of items you will need:

Lumber: Choose sturdy and durable lumber that is capable of supporting the weight of the storage rack.
Screws: Opt for screws that are appropriate for outdoor use and can withstand the elements.
Drill: A power drill will be handy for securing the pieces of lumber together.
Tape Measure: Accurate measurements are vital for ensuring a proper fit.
Saw: Depending on your design, you may need a saw to cut the lumber to the desired lengths.
Screwdriver: A screwdriver can be used in case a drill is not available.
Safety Equipment: Don’t forget safety goggles, gloves, and a mask to protect yourself while working on the project.
Storage Containers: Select sturdy plastic storage containers that can easily fit on the rack.
Optional: If desired, you may also need sandpaper, paint, and brushes for finishing touches.

Make sure to measure and plan accordingly, so you have a clear idea of the amount of lumber and the size of the storage containers needed. Take into consideration the size of your truck and the amount of storage space required.

Gathering all the materials beforehand will help streamline the process and ensure you have everything you need to complete the truck shell storage rack project smoothly.

Step 1: Measure and Plan

The first step in building a truck shell storage rack is to measure your truck bed and plan the layout of the rack. This will help you determine the optimal size and design for your storage solution.

Start by measuring the length and width of your truck bed. Consider any obstacles or protrusions, such as wheel wells or cab contours, that may affect the placement and dimensions of the rack. Take accurate measurements to ensure a proper fit.

Next, determine the height of the rack. Consider the height of the storage containers you will be using and allow enough clearance space to easily access and remove items from the rack.

Once you have the measurements, sketch out a plan or use a design tool to visualize the layout of the rack. This will help you determine the number and size of support beams and crossbars needed.

Take into account any specific storage needs you may have. If you will be storing larger items, adjust the dimensions of the rack accordingly. If you plan to have different sections for organizing different types of items, allocate the appropriate space for each section.

Consider the weight capacity of your truck. Make sure the rack and storage containers will not exceed this limit, as it may affect the stability and safety of your vehicle.

Lastly, review your plan and make any necessary adjustments. Consider how the rack will fit in your truck and how it will impact your ability to access the rest of the truck bed. Ensure that it will not interfere with any existing features or functions of your truck.

By measuring and planning meticulously, you will have a solid foundation for building your truck shell storage rack, ensuring that it seamlessly integrates into your truck and meets your specific storage needs.

Step 2: Gather Tools

Before you can begin building your truck shell storage rack, it’s important to gather all the necessary tools. Having the right tools on hand will ensure that the construction process goes smoothly and efficiently. Here are some essential tools you will need:

Tape Measure: This tool is crucial for taking accurate measurements of the truck bed and the lumber pieces.
Saw: Depending on your design, you may need a handsaw or a power saw to cut the lumber to the desired lengths.
Drill: A power drill will be essential for creating holes and attaching the lumber pieces together securely.
Screwdriver: If a power drill is not available, a screwdriver can be used to tighten the screws.
Screws: Choose screws that are suitable for outdoor use and can withstand the weight of the storage rack.
Level: A level will help ensure that the storage rack is straight and balanced.
Safety Equipment: Don’t forget to wear safety goggles, gloves, and a dust mask to protect yourself during the construction process.

Make sure all the tools are in good working condition and easily accessible before you start building. Check if you have all the necessary drill bits and screwdriver attachments for your specific project.

If you don’t already own some of the required tools, consider borrowing them from friends or family, or renting them from a local hardware store. Having the right tools will make the process easier and allow you to achieve a professional-quality finished product.

Remember to always follow safety guidelines while using power tools and handling sharp objects. Keep the work area clear and organized to avoid accidents.

By gathering all the necessary tools ahead of time, you’ll be well-prepared to tackle the construction of your truck shell storage rack and turn your vision into reality.

Step 3: Prepare the Truck Shell

Before you can start building the storage rack, it’s important to properly prepare the truck shell. This involves ensuring that the surface is clean and free from any debris or obstacles that may hinder the installation process. Here are some steps to follow:

Clean the Truck Bed: Remove any loose dirt, dust, or debris from the truck bed. Use a broom or a shop vacuum to clean the surface thoroughly. This will provide a clean workspace and ensure a secure and stable installation.
Inspect for Obstacles: Check the truck shell for any obstacles that may interfere with the rack installation. Look for features like tie-down points, hooks, or bed liners. Note their locations so you can plan the rack accordingly. You may need to adjust the design or make modifications to accommodate these obstacles.
Protect the Truck Bed: Consider using a bed liner or protective padding on the truck bed to prevent any scratches or damage during the installation process. This will also help in reducing noise and vibrations when the rack is in use.
Address Rust or Surface Damage: If you notice any signs of rust or surface damage on the truck shell, it’s important to address it before installing the rack. Sand down the affected areas, apply rust treatment, and paint or seal the surface to prevent further damage or deterioration.
Mark the Installation Points: Once the truck shell is clean and prepared, mark the points where the rack will be installed. Use a pencil or masking tape to indicate the exact positions of the support beams and crossbars. This will ensure that the rack is installed accurately and securely.

Preparing the truck shell is a crucial step in the installation process. Taking the time to clean, inspect, and protect the truck bed will not only help in achieving a professional-looking finished product but also ensure the durability and longevity of the storage rack.

Step 4: Build the Base

Now that the truck shell is prepared, it’s time to start building the base of the storage rack. The base will provide a stable foundation for the rest of the rack structure. Follow these steps to build the base:

Cut the Lumber: Using the measurements from your plan, cut the lumber pieces for the base. These will typically be the longest pieces that span the width of the truck bed.
Position the Lumber: Place the cut lumber pieces in the truck bed, ensuring they are aligned with your marked installation points. Use a level to ensure that the pieces are straight and even.
Attach the Lumber: Securely fasten the lumber pieces to the truck bed using screws and a drill. Make sure to pre-drill holes to prevent splitting of the wood. Drive the screws through the lumber and into the truck bed to create a solid connection.
Check Stability: Once the base is attached, check the stability of the structure. Apply pressure to ensure that it can withstand the weight of the storage containers. Make any necessary adjustments or reinforcements if needed.

When building the base, it’s important to use sturdy and durable lumber that can withstand the weight of the items you intend to store. Ensure that the base is securely attached to the truck shell to prevent any wobbling or movement during transport.

Remember to take accurate measurements and double-check your installation points to ensure a proper fit. Using a level will help ensure that the base is level and aligned, providing a solid foundation for the rest of the storage rack structure.

Once the base is complete and stable, you can move on to the next step of adding support beams to reinforce the structure and enhance its load-bearing capabilities.

Step 5: Add Support Beams

With the base of the storage rack in place, it’s time to add support beams to reinforce the structure and enhance its load-bearing capabilities. These support beams will provide stability and ensure that the rack can hold the weight of the storage containers without sagging or bending. Follow these steps to add support beams:

Measure and Cut the Support Beams: Using your plan and measurements, cut the support beams to the appropriate length. These beams will typically run perpendicular to the base and provide vertical support.
Position the Support Beams: Place the cut support beams on the base, aligning them with your marked installation points. Ensure that they are evenly spaced and provide adequate support for the length of the rack.
Attach the Support Beams: Securely fasten the support beams to the base using screws and a drill. Drill pilot holes to prevent splitting and screw the beams into place. Make sure they are securely attached to the base and provide a stable framework.
Double Check Stability: Once the support beams are attached, double-check the stability of the overall structure. Apply pressure and ensure that the support beams are strong enough to handle the weight of the storage containers.

When adding support beams, it’s important to choose sturdy lumber that can withstand the weight of the items you plan to store. The support beams should be evenly spaced to provide balanced support throughout the rack.

Take accurate measurements and align the support beams with your marked installation points to ensure a proper fit. By securely attaching the support beams, you will create a solid framework that can withstand movement and provide a stable storage solution.

Once the support beams are in place, you are ready to move on to the next step of installing crossbars to complete the structure of the storage rack.

Step 6: Install Crossbars

Now that the support beams are securely in place, it’s time to install the crossbars. The crossbars will provide horizontal support and create the platform on which the storage containers will rest. Follow these steps to install the crossbars:

Measure and Cut the Crossbars: Using your plan and measurements, cut the crossbars to the desired length. These crossbars will typically run parallel to the base and connect the support beams.
Position the Crossbars: Lay the cut crossbars across the support beams, ensuring that they are evenly spaced and align with your marked installation points. Use a level to check that they are straight and aligned with the base.
Attach the Crossbars: Securely fasten the crossbars to the support beams using screws and a drill. Pre-drill pilot holes to prevent splitting of the wood and then screw the crossbars into place.
Test Stability: Once the crossbars are attached, test the stability of the structure. Apply pressure to ensure that the crossbars can support the weight of the storage containers without bending or sagging.

When installing the crossbars, it’s important to use lumber that is strong and durable enough to hold the weight of the storage containers. The crossbars should be evenly spaced to provide balance and stability to the rack.

Double-check your measurements and alignment to ensure a proper fit. Using a level will help you ensure that the crossbars are straight and aligned with the base, providing a level platform for the storage containers.

Securely attaching the crossbars to the support beams will create a sturdy and reliable framework for your storage rack. Once the crossbars are in place, you can move on to the next step of attaching the storage containers to complete the installation.

Step 7: Attach Storage Containers

With the structure of the storage rack in place, it’s time to attach the storage containers. This step will provide the final functionality and organization to your truck shell storage rack. Follow these steps to attach the storage containers:

Select Suitable Storage Containers: Choose storage containers that are sturdy, durable, and sized appropriately for your needs. Make sure they are designed to fit securely on the crossbars of the rack.
Arrange the Containers: Determine the layout and arrangement of the containers on the crossbars. Consider accessing and organizing the containers in a way that best suits your storage needs.
Secure the Containers: Place the containers on the crossbars and secure them in place using straps, bungee cords, or any other suitable method. Ensure that the containers are tightly secured to prevent movement during transit.
Test Stability: Once the containers are attached, test the stability of the rack by gently shaking it. Make sure the containers are securely fastened and do not shift or wobble. Adjust the straps or attachment methods if necessary.

When attaching the storage containers, consider the weight distribution and load capacity of the rack. Distribute the weight evenly to maintain the stability and balance of the rack.

Choose storage containers that are weather-resistant and designed to withstand outdoor conditions. This will protect your belongings from the elements and ensure the longevity of the storage system.

Take your time to arrange the containers in a logical and organized manner, keeping in mind any specific storage needs or accessibility preferences you have. This will help you make the most efficient use of the available space.

By securely attaching the storage containers to the crossbars, you can ensure that they will remain in place during transportation and provide a reliable storage solution for your truck.

Step 8: Secure the Rack

Once the storage containers are attached to the rack, it’s essential to secure the entire rack to ensure its stability and safety during transportation. Follow these steps to secure the rack:

Check Attachment Points: Inspect all the attachment points of the storage rack, including the base, support beams, crossbars, and container fastenings. Ensure that each connection is secure and tight.
Add Additional Fastenings: Depending on your design and preference, you may consider adding extra fastenings such as tie-down straps, ratchet straps, or bungee cords. These additional fastenings will provide added security and minimize any movement of the rack during transit.
Tighten and Test: Double-check all the fastenings and tighten any screws, straps, or cords as needed. Test the stability of the rack by gently shaking it to ensure that it remains firm and secure.
Perform a Visual Inspection: Take a final look at the entire storage rack and inspect it visually. Ensure that there are no loose parts, damaged components, or signs of wear that could compromise the stability and safety of the rack.

Securing the rack is crucial to prevent accidents, protect your belongings, and maintain the structural integrity of the storage system. By taking the time to properly secure the rack, you can have peace of mind knowing that it will stay in place during your travels.

It is also important to periodically check the rack’s fastenings and attachments for any signs of loosening or wear. Regular maintenance and inspections will help ensure the long-term durability and reliability of the storage rack.

By securing the rack properly, you can confidently transport your belongings without the risk of them shifting or falling during your journey.

Step 9: Test and Make Adjustments

After securing the rack, it’s essential to test its functionality and make any necessary adjustments to ensure optimal performance. By following these steps, you can identify any potential issues and fine-tune the storage rack:

Load and Unload: Load the storage containers with the items you intend to transport or store. Practice loading and unloading the containers to ensure that the rack can handle the weight and that you can easily access your belongings.
Test Stability: Drive the vehicle and test the stability of the rack under normal conditions. Pay attention to any unusual sounds, movements, or vibrations. Ensure that the rack remains secure and the storage containers stay in place.
Check Clearance: Verify that the rack allows enough clearance for the truck and any other objects, such as overhead structures or garage doors. Ensure that the rack does not obstruct your field of vision or interfere with any existing features of the vehicle.
Make Adjustments: If you encounter any issues during the testing phase, make the necessary adjustments. This may include tightening screws, reinforcing connections, or rearranging the layout of the storage containers to improve stability and functionality.

Testing the storage rack and making adjustments is crucial to ensure that it meets your needs and performs as expected. By carrying out these tests and modifications, you can address any potential problems before they become bigger issues.

During the testing phase, it’s important to consider the weight distribution, balance, and overall usability of the storage rack. If you find any areas that need improvement, take the time to make the appropriate adjustments to enhance the functionality and safety of the rack.

Remember to regularly inspect and test the storage rack even after the initial adjustments have been made. This will help ensure that it continues to perform optimally and securely holds your belongings.

Step 10: Optional Add-Ons

Once you have built and tested the basic structure of your truck shell storage rack, you may want to consider adding some optional add-ons to enhance its functionality and customization. These add-ons can be tailored to your specific needs and preferences. Here are a few ideas to consider:

Dividers or Compartments: If you want to further organize your storage space, consider adding dividers or compartments within the storage containers. This will help keep items separate and easily accessible.
Locking Mechanisms: If security is a concern, you can install locking mechanisms on the storage containers to protect your belongings. This will provide an additional layer of safety and peace of mind.
Lighting: Adding lighting to the storage rack’s interior will improve visibility, especially during nighttime use. LED light strips or battery-powered lights can be easily installed to illuminate the storage area.
Tie-Down Points or Hooks: To secure items within the storage containers or to attach additional gear, consider adding tie-down points or hooks to the rack. This will allow you to secure items and prevent them from shifting while on the move.
Ski or Fishing Rod Holders: If you enjoy outdoor activities like skiing or fishing, incorporating holders for skis or fishing rods onto the rack can allow for safe and secure transportation of your gear.

Remember to assess your unique storage needs and consider any specific activities or equipment you plan to transport. These optional add-ons can greatly enhance the versatility and usability of your truck shell storage rack.

Keep in mind that each add-on may require additional tools or materials, so plan accordingly and ensure the compatibility with your existing rack structure. Take the time to research and select high-quality materials and components to ensure durability and functionality.

By adding these optional features to your storage rack, you can further customize it to fit your specific needs and make the most out of your truck’s storage space.