Van lifers and overlanders building out solar and storage setups on Mercedes Sprinter roofs have a modular option in Orion Van Gear's Roof Deck Panels 2.0, which the brand positions as an upgrade over its original 1.0 design with a fully flush, countersunk hardware system.
The panels are built from 8-gauge aluminum with UV-resistant powder coating and come in seven different sizes (labeled A through E, with D having two sub-variants) so owners can mix and match panels to fit fans, hatches, and air conditioning units. Orion states the flush surface, achieved through custom-engineered 316 stainless steel countersunk bolts, is intended to eliminate bolt heads that could otherwise interfere with walkable solar panel installations. The company also states the panels are roughly 30% lighter than competitor panels and are compatible with 2"x1" or 3"x1" extruded crossbar systems, including Orion's own Sprinter and Transit rack lines.
The Panel A size reviewed here is listed at $144.00, discounted 10% from $160.00. Other panel sizes are priced from $117.00 to $148.50 depending on dimensions.
This specific product carries a 5.0 out of 5 rating from 14 reviews. Verified buyers describe installing the panels alongside walkable solar arrays and Maxxair fans, with several reviews specifically praising ease of DIY installation ("Super easy to install," "installed mainly by myself with minimal tools") and fit accuracy. A few reviewers noted needing to drill a small number of additional holes depending on their specific rack setup, and one reviewer mentioned Orion issued a refund after helping them identify the correct panel sizing for their build.
With a strong, verified review record and a design aimed squarely at the walkable-solar van conversion crowd, Orion's Roof Deck Panels 2.0 appear to be a well-regarded option for Sprinter and Transit van builds. See current panel pricing on Orion Van Gear's site.
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