Sprinter Roof Deck Panels 2.0 – New Flush Surface Design (Multiple Sizes)

Orion Van Gear Modular Sprinter Roof Deck Panels 2.0

The Orion Van Gear Modular Sprinter Roof Deck Panels were the first-ever modular roof deck system designed specifically for 10-series crossbars, setting the benchmark in the van world. While others have tried to imitate our innovation, we remain unmatched in quality, functionality, price, and drive to continually improve.

With six different-sized panels, our system offers unparalleled versatility for Stealth+ Sprinter Roof Rack owners, no matter your roof configuration. Compatible with all three Sprinter wheelbases—144, 170, and 170 EXT—you can customize your setup by mixing and matching individual panels or selecting pre-configured bundles. For a perfect fit, we even offer CAD-Verified Layouts upon request.

Introducing a Van World First—Flush Surface Design

After over a year of development, our newest version is a true breakthrough: the first-ever fully flush countersunk hardware system for modular roof deck panels. This innovation eliminates bulky button heads, taking functionality and design to a new level. Key features include:

• Seamless, 100% Flush Surface: No bolt heads to catch your feet, gear, or equipment.
• Perfect for Walkable Solar Panels: No need to avoid bolt heads when installing walkable solar panels, ensuring maximum utility, aesthetics, and longevity of your solar panel system.
• Improved Longevity and Efficiency: A completely flush surface minimizes wear and tear on panels, protecting your investment and ensuring optimal solar output for years to come.
• 316 Stainless Steel Deck Bolts: Custom-engineered for exceptional durability and corrosion resistance. These are not off-the-shelf bolts; they feature a custom countersunk angle and precise bolt length specifically designed to integrate seamlessly with the extrusion system, ensuring a perfect, flush fit.

This patent-pending design redefines what modular roof deck panels can be. Our panels are more functional, more durable, and designed to withstand even the toughest adventures. Scroll through the product images to explore example layouts and find inspiration for your perfect setup!

Panel Sizes:

• Panel A: 21.75" L x 26.25” W
• Panel B: 28.5" L x 17.5” W (for Maxxair Fan)
• Panel C: 31.85" L x 17.5” W
• Panel D: 28.5" L x 8.3 - 9.3” W (for small AC units & hatches)
• Panel D2: 37" L x 7" W (for large AC units)
• Panel E: 12.3" L x 26.25" W
• Find more compatible Sizes Here

Custom Configuration Assistance

Step 1: Design your roof layout and determine which panels fit best. Fill out this form for a free CAD-verified layout to ensure optimal configuration when paired with our racks. If you have fans, air conditioners, hatches, or other items through the roof jump to step 3. 

• Calculate crossbar spacing by subtracting 2" from the length of each panel (gives you the distance needed between crossbars). For Example, a B panel that is 28.5” long, would require 26.5” between 2 crossbars as each panel overlaps the top of each crossbar by 1”.

Step 2: Email us to verify the panel configuration. If you have appliances mounted (fan, AC, or hatch), provide the model name/number and specific measurements using the reference images below.

1. For rear-mounted appliances, measure the distance from the rear plug to the rear edge of the appliance.
2. For forward-mounted appliances, measure the distance from the front seam to the front edge of the appliance.
3. Measure the distance between all roof appliances. (EG. between fan and AC)

Key Features:

• The Most Innovative Sprinter Roof Deck System on the Market: Featuring a patent-pending flush-mounted hardware design for a completely seamless surface. Built from durable, lightweight aluminum and coated with UV-resistant powder for long-lasting protection.

• Customizable Modular System: Choose from 6 Sprinter-specific panel sizes for perfect compatibility, or mix and match with 4 Transit panel sizes if needed. Request a CAD-verified layout. This allows for nearly unlimited combinations to create full decks, partial decks, or single-panel installations. They sit flush with the rack's top edge for improved aerodynamics and usability.

• 100% Flush Surface Design: No bolt heads to catch feet or gear. Ideal for installing walkable solar panels without worrying about bolt placement, ensuring maximum utility and efficiency.

• Accommodates Appliances: Designed to fit around fans, hatches, and most air conditioning units with ease.

• L-Track Compatible Mounting Holes: Strategically placed for secure gear attachment, perfect for adventure-ready setups.

• Enhanced Accessory Compatibility: Enhance functionality. Seamlessly integrates with our Drop-Down Solar Brackets, Starlink Brackets, and other roof accessories for ultimate versatility.

• 316 Stainless Steel Custom Hardware: Features custom-engineered countersunk bolts designed for a perfect, flush fit. These are not off-the-shelf parts, ensuring superior durability and corrosion resistance.

• Easy & Fast DIY Installation: A straightforward DIY upgrade—no drilling required. Installation is quick and hassle-free, requiring only basic tools and minimal time.

• Proudly Made in Oregon: Designed and manufactured with precision and care to meet the highest quality standards.

• FREE SHIPPING: Complimentary shipping to the lower 48 states included.

Compatibility

Compatible with all racks using 2" x 1" or 3" x 1" extruded aluminum crossbars including our Sprinter Roof Rack and Transit Roof Rack, designed for 52.5" to 62" wide racks. Each panel sits 1" over each side of a crossbar. You can mix and match these deck panels with our Transit Deck Panels. For personalized configuration assistance, please request a Cad-Verified Layout.

Frequently Asked Questions (FAQ)