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Van Build: Chapter 2 Orion’s Roof

Orion Van Gear Chapter 2

Table of Contents

Chapter 2 is all about the roof! After our windows were completed, we focused on our roof. This is where our solar panels and deck panels would live on top of. We did extensive research and decided that Orion Van Gear was the best company for all our projects. Not only did we get our roof rack/deck plus solar panels from Orion, we also got our MaxxAir Fan. The process of getting everything we need was easy. They are super personable and chatted on social media and email. Once the van is done, we plan to visit them. We want to meet in person and show them what they helped create.

Ford Transit Stealth+ Roof Rack

We knew we needed a roof rack for our Ford Transit, but we didn’t want something bulky or loud on the road. The Orion Van Gear Stealth+ Roof Rack felt like the right fit—low-profile, sturdy, and easy to install. No drilling, no unnecessary hassle. Just a solid, lightweight aluminum rack that bolted right onto the van. What we love most is how modular it is. We started simple, but as our build evolved, we could add roof deck panels, solar, and extra storage without having to rethink the whole setup. It’s been the perfect balance of function and flexibility.

Another thing we appreciated right away was how quiet it is while driving. We’ve had racks in the past that created a constant hum on the highway, but this one barely makes a sound. It also sits low enough that it doesn’t feel like we’re hauling extra bulk on the roof, which helps with fuel efficiency. And because it has built-in T-slots, mounting things like solar panels or extra gear is easy without needing a bunch of extra brackets. Over time, we’ve realized how much we like having a setup that can grow with us instead of feeling locked into one configuration. It’s one of those upgrades that just makes van life smoother.

Orion Van Gear Roof Rack

Walkable Panels

We wanted a roof deck that felt solid underfoot but didn’t add a ton of weight to the van. The Orion Van Gear Roof Deck Panels were exactly what we were looking for. They bolt right onto the Stealth+ Roof Rack, creating a stable, slip-resistant surface that makes it easy to move around up top. It’s good for hanging out, cleaning the solar panels and is super sturdy! It’s also nice knowing we don’t have to balance on skinny crossbars or worry about denting the roof every time we step up.

One of the best parts is how they integrate seamlessly with everything else. The design prevents water from pooling and plenty of space to mount solar panels.

Orion Van Gear Roof Rack Deck Panels
Orion Van Gear Roof Rack Deck Panels
Orion Van Gear Roof Rack Deck Panels

Solar Panels

We wanted solar panels that could handle all our power needs without taking up too much space. After a lot of research, we went with two Rich 250-Watt Monocrystalline Solar Panels. They fit perfectly with our Orion Van Gear Roof Deck Panels and give us plenty of power. Even on cloudy days, they still pull in a good charge, which is a huge plus when we’re parked in the shade. They also sit low on the roof, so there’s no extra wind resistance when we’re driving.

What we love most is how reliable they are. Once we installed them, we didn’t have to think about them—they just work. The high-efficiency cells keep everything charged, from our fridge to our laptops. No constant adjustments, no maintenance headaches. Just free power from the sun, keeping us off-grid and on the road longer.

Orion Van Gear, Roof Rack, Panels & Solar Panels

Every part of this van build has been about making life on the road easier. The Orion Van Gear Stealth+ Roof Rack gave us a solid foundation. The roof deck panels made the space up top usable. And our solar panels keep us powered no matter where we park. Everything works together, and we love how simple it all feels.

But none of it would matter without good airflow and natural light. Check out our Chapter 1 Windows blog for more information on our window selection! It helped make the space feel more open and gave us better ventilation. Next is the Maxx Air Vent, so check it out next! 

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HI!! We're Danielle and Malcolm

We're a couple of full time remote workers looking to explore the United States in our van and the world by air. In 2024, we purchased a Ford Transit and started building out our DIY van, that will be our permanent home when completed. Between the build and our jobs, we also love to travel to new places and visit our family and friends that live all across the USA.

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