by ** Orion Van Gear (manufacturer direct)
Material: Powdercoated aluminum Design: Ultraformfitting, modular, lightweight, rustresistant Custom designed for maximum rooftop utility (luggage, solar panels, rooftop fans/AC cutouts) Proudly made in Oregon, USA Backed by a limited lifetime warranty Requires basic mechanical skills but typically uses factory roof mounting points; clear instructions provided[4][5].
| Specifications | ** |
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Compatibility:
The Orion Van Gear roof rack is considered an outstanding choice for campervan and RV conversions due to its lightweight, adjustable, and durable design, plus seamless compatibility with common rooftop accessories[1][2][3]. The rack’s engineering and installation features specifically address the needs of both DIY enthusiasts and professional upfitters.
What Makes It Ideal for Campervan Conversions
- No-drill, no-cut installation: Mounts directly to factory roof pins or rails using included adapters and hardware, minimizing installation risk and preserving vehicle value[1][2][4].
- Aluminum construction: Lightweight (as low as ~76–102 lbs.), rustproof, and strong, essential for maximizing roof payload and maintaining handling and fuel economy[1][2][3][4].
- True compatibility: Available for major van platforms (Ram Promaster, Mercedes Sprinter, Ford Transit), and can be tailored to different roof lengths and heights[1][2][3][5].
Key Features and Benefits
- 100% adjustable crossbars: Move or add crossbars easily to suit solar panels, fans, rooftop tents, storage boxes, etc.[1][2]
- Upgradable and modular: Pre-engineered slots and 8020 channels let you add ladders, awnings, surfboard/paddleboard carriers, lighting, and more—often without drilling into the rack[1][2][3].
- 360-degree privacy: Side shrouds and fairings hide roof contents (solar panels, wiring, AC units) from view at ground level—helpful for stealth camping and design aesthetics[1][2][3].
- Aerodynamic and low profile: Reduces wind noise and drag while still offering enough vertical clearance for bolt-on accessories or walkable solar panels[1][2][3].
- Premium finish: UV-resistant black powder coating and stainless hardware resist corrosion and look professional for years[1][2].
What to Look For When Buying
- Fitment compatibility: Match the rack to your van’s length, height, and generation—double-check against manufacturer templates or custom CAD services[1][3][5].
- Payload and accessory support: Verify weight ratings relative to your intended gear (solar panels, roof boxes, etc.) and ensure accessory mounts (e.g., for awnings, ladders) work with your priorities.
- Installation support: Look for thorough instructions, included hardware/kits, and tech support. Orion provides detailed guides and even install videos[1][4].
- Customizability: Prioritize modular racks that simplify configuring and re-configuring roof layouts as your needs change[1][2][3].
Common Mistakes to Avoid
- Assuming universal fit: Not all racks fit every van shape and year; measure and confirm[1][3].
- Overloading: Don’t exceed roof rack or van roof weight ratings—factor in everything mounted above.
- Forgetting accessory compatibility: Some racks require specific mounts or adapters for awnings/solar panels—plan all attachments during purchase[1][2].
- Skipping sealant on hardware: When necessary, use threadlocker and anti-seize as Orion recommends, especially for long-term, vibration-prone installs[4].
Best Use Cases
- Weekend warriors: Quick install, minimal weight penalty, modularity for swapping seasonal gear (e.g., boards in summer, storage box in winter)[1][3].
- Full-time living: Large surface area for solar, 12V AC/fans, Starlink, walkable panels, and roof privacy. Modular channels simplify updating gear as needs evolve[3][4].
Budget Considerations & Value Analysis
- Orion’s rack costs are very competitive for premium segment options, often including free shipping and full hardware kits[1][3][5].
- Given all-aluminum construction, US manufacturing, and lifetime durability, the higher upfront investment pays off for vans that will be used hard or kept long-term.
- Cheaper racks may compromise with steel (heavier, rust-prone), less adjustability/modularity, or require drilling that voids warranties.
- The rack’s ability to grow with your van saves both money and installation time over repeated upgrades[3].
Choose the Orion Van Gear rack if you want a future-proof, robust, and modular base for your campervan roof—whether for weekend escapes or full-time adventures.
The top alternatives to a standard campervan/RV roof rack include the Unaka Gear HSLD, Flatline Van Co Low Pro, Safari Roof Rack, Yakima LockNLoad, and Aluminess Modular/Custom. Each varies by weight, modularity, customization options, and cost, suiting different van life needs[1][2].
| Product | Pros | Cons | Price Range |
|------------------------------|--------------------------------------------------------------------|-----------------------------------------------------|------------------|
| Flatline Van Co Low Pro | Lightweight (~64 lbs), modular, aerodynamic, fits solar panels | Not a full deck, mid-range price | $1,695–$1,995[1] |
| Unaka Gear HSLD | Highly modular, custom wind fairing, 80/20 t-slots | Similar price to Low Pro, availability varies | ~$2,000[1] |
| Safari Roof Rack | Full roof deck, robust, L-Track system, accessory-friendly | Heavy (150–185 lbs), increases vehicle height, cost | ~$4,000[1] |
| Yakima LockNLoad | Modular, T-Slot system, mid-lightweight, flexible sizing | Assembly complexity, accessory prices add up | $729–$979[2] |
| Aluminess Modular/Custom | Highly configurable, custom cut-outs, lightweight aluminum | Highest cost, long lead times, variable shipping | $2,700–$3,800+[2]|
When to choose each:
- Low Pro/Unaka Gear HSLD: When you need a modular, aerodynamic rack for solar panels and occasional gear, at a moderate price and weight[1].
- Safari Roof Rack: When you want a roof deck for lounging or stargazing and are not as concerned about weight or added height[1].
- Yakima LockNLoad: If you want flexible mounting options, plan to frequently change mounted accessories, and value mid-level cost[2].
- Aluminess: For maximal customization around vents/AC, professional fit, or unique layout needs, and budget/lead time are less restrictive[2].
Performance for van life use:
- Low Pro/HSLD excel for solar, lights, and modular accessories while minimizing aerodynamic drag.
- Safari caters to social/recreational uses but adds more weight and clearance[1].
- Yakima is best for users who frequently reconfigure racks and loadouts.
- Aluminess is optimal for owners with many roof features or demanding layouts.
DIY options exist for significant cost saving, but require confidence in measuring, mounting, and finishing for watertight and stable results[1].
Choose based on your primary use—solar vs. deck vs. reconfigurability—and balance weight, installation complexity, and price for your specific van life goals.
Installing a roof rack on a campervan involves careful planning and attention to detail to ensure safety, function, and a watertight fit.
Step-by-step overview:
- Verify compatibility with your van and gather all hardware.
- Position and loosely install adapter brackets in the OEM roof rails or aftermarket tracks, following manufacturer guides for precise mounting points[1][2][4].
- Attach side rails using provided bolts and washers, keeping hardware slightly loose for adjustment[2].
- Add crossbars and components, aligning them with any roof features (fans, solar panels, etc.), then snug them in place[1][2].
- Install fairings and accessories if included, ensuring alignment[2].
- Once everything is aligned and panels (if any) are in place, tighten all hardware to the specified torque, using anti-seize and thread locker as directed[1][3].
- Check all connections, clean up excess fluids, and confirm nothing is pinched or misaligned.
Common mistakes to avoid:
- Over-tightening hardware, risking stripped threads or damage to rails/van roof[2].
- Installing brackets or washers in the wrong orientation (track washers must sit flat against the rail)[1].
- Using incorrect bolt lengths, which can cause leaks or insecure attachment[1].
- Failing to measure mounting points from the correct datum, leading to misalignment[4].
Tools and materials needed:
- Socket wrench set
- Torque wrench
- Measuring tape
- Allen keys
- Anti-seize lubricant & thread locker
- Isopropyl alcohol (for cleaning)
- Ladder and safety gear[1][2]
Estimated installation time:
4–8 hours for a DIY installer with basic skills; shorter for experienced builders[3].
DIY tips vs. hiring a pro:
- DIY is feasible for those comfortable with tools and following detailed instructions.
- Hire a professional if you lack tools, have a highly contoured roof, or need holes drilled—any mistakes can compromise weatherproofing or safety.
Safety considerations:
- Secure ladder and use fall protection.
- Never overtighten hardware near roof seams or wiring.
- Avoid missteps that could damage the van’s weatherproofing.
Pro tips from experienced van builders:
- Loosely fit all parts before final tightening to allow adjustment[1][2].
- Apply anti-seize to all bolts and thread locker to screws for durability[1][3].
- Clean anti-seize spills with isopropyl alcohol to prevent staining[1].
- Double-check the rack’s fit after mounting, especially around added components (solar/fans).
Staying methodical, following instructions, and double-checking alignments are key for a secure, rattle-free, and weatherproof installation.