Aerodynamic headache rack

[oil pan 4]

For 1999 Dodge Dakota.
Because the ones I can buy are expensive, look stupid, don't do what I need, stick way up above the cab, are right up against the back window, ect.
To have it be aerodynamic it will have 2 key features.
It won't stick out or above the cab.
Not be there, easy for me to remove but no one else, 4 bolts.
My leaf light bar tests showed at least a 20% range reduction when putting something above the car.
My list of requirements are:
Not be made of exhaust pipe.
Be made of thicc steel tube.
Not further degrade the barn like Dodge aerodynamics.
Have a stand of at the top for reasons.
Also offer back window protection, expended metal.
Attach to the sides of the bed not down in the bed, for maximum carrying room.

[freebeard]

Do you have a tubing bender? How do you make it removeable but not?

To fill the frame I'd consider this perf stair tread:


https://external-content.duckduckgo....0c5&ipo=images

Dimple died both ways. Heavy enough it wouldn't need much framing, maybe a triangular flange at the ends. It just looks metal.

[oil pan 4]

I have some of that stainless steel decking.
I'm going to have to by some, as I don't have a big enough piece.
I have a roll bar for a bronco I think to cut up to make the frame from.

[freebeard]

What do you think about having half the diameter exposed as frontal area, such that it acts as a wickerbill?

[oil pan 4]

It would probably be almost as bad as a solid barrier.

[freebeard]

So put it in enfilade and add a real wickerbill?

My thought was to treat the three sides of the cab instead of just the top as on race cars.

[oil pan 4]

Tri lug nuts and security torx for security.

[j-c-c]

Originally Posted by oil pan 4

For 1999 Dodge Dakota............
To have it be aerodynamic it will have 2 key features.
It won't stick out or above the cab.......

Clariify please

[oil pan 4]

Originally Posted by j-c-c

Clariify please

Anytime I can find pictures of the headache rack installed they're always sticking up like 4 to 6 inches above the roof line.

[j-c-c]

Originally Posted by oil pan 4

For 1999 Dodge Dakota.
Because the ones I can buy are expensive, look stupid, don't do what I need, stick way up above the cab, are right up against the back window, ect.
To have it be aerodynamic it will have 2 key features.
It won't stick out or above the cab.
Not be there, easy for me to remove but no one else, 4 bolts.
My leaf light bar tests showed at least a 20% range reduction when putting something above the car.
My list of requirements are:
Not be made of exhaust pipe.
Be made of thicc steel tube.
Not further degrade the barn like Dodge aerodynamics.
Have a stand of at the top for reasons.
Also offer back window protection, expended metal.
Attach to the sides of the bed not down in the bed, for maximum carrying room.

Well, in order to assist, a few details should be sorted out to better understand your overall objectives here.
You have mentioned a few "requirements", but knowing why is also useful ie, define the problem.
For instance: "Thick steel tube", why?
Define "stand", and why?
"Back window protection", that seems redundant as that is what a headache rack is mostly.
Attachment to the sides and not to the bed base seems to make "thick steel tube" rather superfluous IMO.
Any aero concerns are addressed here mainly by two aspects, do nothing to increase frontal area, and minimize any gap between existing cab and headache rack, which seems to state you dislike, everything else is mainly cosmetic and functionality. Adding fixed lights on top negates any and all aero achievements achieved elsewhere and changes the main design IMO to a headache rack that is a light mount. Make the desired headache rack longer longitudinally for improved aero takes up bed space that is not acceptable for "maximum carrying room"?
This is my take based on what is shared so far on the project.