I have a headache rack on my truck but my current mounting method has failed. I used four sheet metal screws per side and during recent off roading, they pulled out of the bed metal.

My headache rack has a mounting style much like this one, but the base isn't as long.


I can not access the area where the screws go through the metal because of the bed structure so I can not use bolts and nuts.
I was wondering of anyone here has a similar type of rack and how you have mounted it. I have four lights on mine so it is pretty top heavy.

 

You should be able to bolt and nut them. You have a plastic bedliner in the way?

 

Could you use something like a bed anchor mount? Like the anchor's in the pic? Then you wouldn't have to get underneath.

http://www.amazon.com/No-Drill-Truck.../dp/B000ICGDZQ

 

There is a plastic bed liner. I pulled it back and the holes are still not accessible.
I guess I'll have to relocate the rack to put the holes in the open space.

 

From your description it sound like you could use a large square washer to reinforce the bed rails. Maybe cut a square piece of steel to fit under the bed rail in that groove. The larger the square the more spread out the load will be.
The same technique is used to put Ramcharger seats in a first gen Ram. I was not quite sure how to describe it but you kinda get what I mean?

 

OK, I just went out and gutted the bed. Removed the toolbox, junk, and bed liner. It is nasty under there. The liner has probably been on since the dealership- it has a MOPAR sticker.

Anyway, here are some pictures to show you what I am talking about.
Sorry for the horrid quality.




The two holes at the very front edge and the two towards the state pocket are the ones from the headache rack.


Difficult to see in this picture, but the front holes and back holes are in the covered parts