Tonneau covers and headache racks are two of the most popular truck accessories on the market. But can you use both at the same time on your pickup truck? The short answer is yes, you can mount a headache rack on trucks with tonneau covers, but there are some important factors to consider.
In this comprehensive guide, we will cover everything you need to know about combining tonneau covers and headache racks, including:
What Are Tonneau Covers and Headache Racks?
Defining Truck Tonneau Covers
A tonneau cover is an accessory that goes over the bed of your pickup truck. Tonneau covers come in soft, hard, and retractable styles. The main benefits of adding a tonneau cover are:
- Protection – Keeps cargo safe from weather and theft
- Improved gas mileage – Smoother air flow improves MPG by up to 10%
- Styling – Sleek, finished look for your truck
Understanding Headache Racks
A headache rack, sometimes called a cab protector or cab guard, is a metal structure that mounts to the bed of your truck directly behind the cab. Key benefits include:
- Protection – Prevents cargo from slamming into the back window in a collision
- Organization – Provides an anchor point to strap down loads
- Style – Rugged, truck-like appearance
Truck Bed Anatomy 101
Where Does the Tonneau Cover Mount?
On most modern pickup trucks, tonneau covers mount to rails that run along each side of the truck bed. The cover attaches with clamps or a snap-in rail system, allowing it to be easily removed.
This means the tonneau cover fits in between the bed rails rather than sitting on top of them. This is an important distinction when it comes to compatibility with headache racks.
Headache Rack Mounting Points
Headache racks typically mount to the stake pockets or pre-drilled holes along the top edge of the truck bed. Most models also attach to the cab itself with brackets.
This installation requires access to the bed rails that would be partially obscured by a tonneau cover sitting atop the rails.
Which Tonneau Covers Work with Headache Racks?
Go For In-Rail Mounting System
The most headache rack-friendly tonneau covers use an in-rail mounting system that attaches clamps or rails inside the bed channels. Examples include:
- Folding covers
- Retractable covers
- Roll-up covers
- Low-profile hard covers
As long as the tonneau leaves the top of the bed rail free, it should be fully compatible with headache rack installation.
Avoid Top-Mounting Designs
Full-size, thick tonneau covers that sit atop the bed rails generally do not work with headache racks. The cover blocks access to the stake pockets, preventing proper rack mounting. These styles include:
- One-piece fiberglass covers
- Thick polymer covers
- Heavily padded covers
Modifying one of these covers to work with a headache rack would require extensive fabrication work in most cases. For best results, go with an in-rail system.
Matching Tonneau Covers and Racks
Consider Cover-Specific Racks
For maximum compatibility, you can purchase a headache rack designed specifically for use with a tonneau cover, such as:
These racks include custom brackets to mount around or underneath the tonneau cover.
Mix and Match Components
You also have the option to choose any standard headache rack and compatible tonneau cover. Look for racks with cab-mounted brackets that do not rely solely on stake pockets for installation.
With some careful measurement and drilling, a universal rack and tonneau can be mated together.
Consider Professional Installation
Unless you are highly experienced with truck modifications, having a professional handle the installation is wise. An expert can ensure proper bracket placement and structural integrity.
Modifying Incompatible Tonneau Covers
Adjusting Fiberglass Covers
If you have a fiberglass tonneau cover and want to add a headache rack, it is possible with some custom work:
- Carefully cut clearance holes in the tonneau for the rack legs
- Install nylon bushings around holes to prevent cracking
- Seal all cuts with weatherproof sealant
- Consider adding support brackets underneath
This approach requires meticulous planning and skill with fiberglass fabrication.
Altering Vinyl Covers
An auto upholstery shop may be able to modify a vinyl tonneau cover to work with a headache rack by:
- Adding slit openings for the rack legs
- Installing grommets to prevent tearing
- Patching and re-sealing the vinyl
- Securing the cover around the rack
However, results will depend on the material, design, and shop. This option requires removing the cover.
Choosing Your Setup
Assess Your Needs
When deciding on a tonneau cover and headache rack combo, assess:
- Cargo you’ll be hauling (size, weight)
- Off-road usage
- Preference for soft vs hard covers
- Budget for accessories
- Openness to custom modifications
This will help narrow down compatible options.
New Truck Purchase
If you are purchasing a new truck, look for standard stake pockets or pre-drilled mounting points to allow easy rack installation later on. Some truck beds are smooth, requiring aftermarket drilling.
Consider Future Plans
Be sure to think about any other accessories you may want to add down the road, like a fifth wheel hitch, that could impact the headache rack position.
Planning ahead will provide for the most flexibility.
Maintaining Your Truck Rack and Tonneau
Protect the Finish
Use truck soap and wax to keep your headache rack and tonneau cover looking like new. Rinse off road salt and grime frequently.
Check Mounting Points
Periodically inspect all mounting brackets, clamps, and hardware. Look for signs of looseness or wear. Tighten or replace components as needed.
Lubricate and Adjust
Keep hinges, slides, and moving parts lubed and adjusted on folding or retractable covers. This prevents binding and damage over time.
Touch Up Damage
Touch up any chips or scratches right away with color-matched paint to prevent rust. Replace damaged rack sections or tonneau panels that cannot be fixed.
Proper care will keep your headaching rack/tonneau combo lasting for years to come!
Conclusion
The bottom line is yes, with the right components, you can absolutely run a headache rack and tonneau cover together on a pickup truck! Mounting a rack requires careful selection of a tonneau designed to fit in the bed rails rather than on top of them. Products like Backrack’s tonneau bracket system make the combo plug-and-play.
With a little fabrication work, even more truck setups can accommodate both accessories. Just be sure to match your needs, budget and installation skills when picking components. With proper maintenance, your truck will enjoy the benefits of cargo protection and style. Happy trucking!