Campervan Roof Racks Explained: Benefits, Installation & Key Setup Tips
Shop VW Crafter Roof Racks & MAN TGE Roof Racks
Fitting a roof rack to your MAN TGE or VW Crafter, is often the first major upgrade for any van build and for good reason. Whether you're configuring a long-wheelbase off-grid touring rig or just need extra room for a kayak, a heavy-duty rack transforms unused roof space into your van's utility hub.
For popular vans like VW Crafters, VW Transporters, MAN TGEs, Mercedes Sprinters, vehicle-specific racks become the backbone of your exterior build. It's much more than extra storage space - it gives you a solid foundation to mount crucial gear.
What Is a Campervan Roof Rack?
A campervan roof-rack is a custom-fitted platform mounted to your vehicle's roof, designed to haul bulky gear and maximise off-grid living space.
Unlike basic crossbars (which only support a couple of narrow mounting points), a full-length roof-rack spreads weight evenly across the entire vehicle’s roof. This gives you a flat, rigid workspace capable of carrying far more than just extra luggage.
Why fit a full-length rack instead of basic bars?
Full- length roof racks allow you to easily mount solar panels alongside large adventure kits like kayaks, paddleboards, recovery tracks, or oversized storage boxes. Our modern racks use lightweight, powder-coated aluminium which gives you maximum structural strength without adding unnecessary weight or rusting over time.
Roof-rack systems are built using separate, interchangeable components that connect together, rather than being manufactured as a single fixed piece. The T-track slots and integrated mounting channels allow you to rearrange tie-down points, LED light bars, and awnings as your setup evolves.
Quality roof-racks are engineered for specific van models (such as Sprinters, Man TGEs, or Transporters and Crafters) to bolt directly into factory mounting points without compromise.
They are also commonly fitted to:
- Off-road campervans
- Overland campers
- 4x4 campervan builds
The Benefits of a roof-rack
A roof rack is often one of the first modifications van owners make. It fundamentally changes how you use, pack, and live out of your vehicle.
1. Maximise Interior Space
The biggest enemy of a comfortable van build is internal clutter. Bulky gear like paddleboards, surfboards, spare wheels, or extra fuel cans deplete floor space rapidly, turning your living room into a cramped storage locker. Mounting large, dirty, or awkwardly shaped kit to the roof frees up precious square footage inside the cabin, leaving your living space clear for eating, sleeping, and relaxing as soon as you park up.
2. Create an Off-Grid Power Hub
If you plan to live or travel off-grid, your roof is prime real estate for power generation. A full-length rack provides a flat, rigid platform to secure large solar panels flat against the frame, protecting them from wind flex while avoiding the need to drill straight through your van’s roof metal. You can easily pair solar panels alongside roof vents, skylights, and starlink mounts without sacrificing usable space.
3. Heavy-Duty Equipment & Gear Mounting
Unlike standard crossbars with limited weight capacities, a dedicated full-length rack distributes heavy loads evenly across all factory mounting points. Integrated T-track channels along the extrusions let you bolt on recovery tracks, high-lift jacks, gas bottles, and awnings wherever you need them. Everything stays locked down securely, easily accessible, and out of the way until you hit the trails.
4. Vehicle Protection
Storing sizable, heavy or irregular cargo directly on a van roof or securing items to basic clip-on bars can easily dent, scratch, or stress the thin sheet metal. A custom-fitted aluminium rack sits slightly elevated above the roofline, transferring the entire load straight into the reinforced structural pillars of the vehicle body. This protects your paintwork, prevents expensive bodywork damage, and stops water pooling around flexed metal seams.
5. Added Protection & Off-Road Utility
Beyond carrying gear, a sturdy roof rack acts as an armor shield for the top of your vehicle. It deflects low-hanging branches on tight forest trails and provides a solid anchor point for front LED light bars, perimeter camp lighting, and side awnings. For overland builds, it can even serve as a stable rooftop deck for viewing spots or an elevated sleeping platform for a rooftop tent.
What to Consider Before Buying a Roof Rack
Choosing the right roof rack depends on how you plan to use your van, where you want to travel, and what gear you need to haul. Avoiding a costly buying mistake means looking beyond aesthetics and evaluating how a rack fits into your total van build.
1. Vehicle Platform, Wheelbase & Roof Height
Roof racks are rarely one-size-fits-all. Vans like the Mercedes Sprinter, VW Crafter, and MAN TGE come in Short, Medium, Long, and Extra-Long Wheelbases alongside varying roof heights. A rack designed for an MWB Sprinter will not align with the factory mounting tracks on a LWB version. Always verify that the rack geometry matches your exact model, year, and roof profile.
2. Vehicle Roof Load Limits vs. Dynamic Weight
There is a critical difference between how much weight your rack can hold and how much weight your van’s roof is rated to carry. Consider both the maximum weight allowed on the roof while your vehicle is driving and the weight the roof can safely support when parked up (e.g. two adults sleeping in a roof tent).Exceeding these limits impacts handling, increases body roll in corners, and poses a serious safety risk. Remember to always factor in the weight of the aluminium rack itself before calculating how many kilograms of gear, solar panels, and awnings you can safely carry.
3. Solar Panel & Roof Vent Layouts
If you are planning an off-grid electrical system, your roof rack layout needs to be planned alongside your interior layout. Position roof vents (like MaxxAir fans) and skylights first, as these require clear openings. Your rack needs modular crossbars that can be slid forward or back to fit flush around these cutouts while still leaving flat real estate for rigid solar panels.
4. Awning & Accessory Mounting Compatibility
Not all awnings attach to every rack in the same way. If you plan to mount a roll-out or 270-degree awning, ensure the rack features integrated T-slot channels or compatible side-bracket mounts. The same applies to perimeter lighting, recovery boards, and ladders—buying a rack with standardised extrusions ensures you can bolt on accessories from different brands without custom fabrication.
5. Total Vehicle Height & Clearance
Fitting a platform rack, recovery tracks, and a light bar will add anywhere from 10cm to 30cm to your overall vehicle height. If you drive a High Roof Sprinter or Crafter, this extra height can push you over standard height barriers, limit entry into underground car parks, or bump you into higher toll road categories. Measure your current clearance before committing to tall accessories.
6. Wind Resistance & Fuel Economy
Adding a large, square platform to your roof alters the aerodynamics of your van, which can lead to wind noise at highway speeds and increased fuel consumption.
The Golden Rule:
The most common mistake is choosing a rack based purely on its rugged looks. Start by listing everything you plan to put on your roof—now and two years down the line—and pick a modular system that gives you room to grow.
Roof Rack Maintenance Requirements
Roof racks require relatively little maintenance, but regular inspections are recommended.
Check:
- Mounting bolts and fixings.
- Corrosion on steel components.
- Accessory mounting hardware.
- Load securing points.
- Electrical wiring for roof-mounted lights.
Regular cleaning is particularly important if the vehicle is used off-road or in coastal environments.
Frequently Asked Questions About Campervan Roof Racks
How much weight can a campervan roof rack carry?
How much weight your setup can safely carry depends on two distinct numbers: the weight limit of the roof rack itself and the maximum roof load rating of your van. For popular vans like the Mercedes Sprinters, VW Transporters and Crafters, or MAN TGEs, vehicle manufacturers typically set dynamic roof limits between 75 kg and 150 kg (including the weight of the rack itself). Exceeding this limit affects your vehicle's centre of gravity, handling, and braking performance. Static limits are significantly higher, often 300 kg or more, which easily accounts for the weight of a roof-top tent, gear, and occupants sleeping upstairs.
Always check your van’s owner manual for its maximum roof load rating, deduct the net weight of the aluminium rack, and the remaining figure is the maximum weight of gear you can safely carry on the road.
Can I fit solar panels to a roof rack?
Fitting solar panels to a roof rack is actually one of the safest and most efficient ways to power an off-grid electrical setup. Instead of gluing flexible panels directly to your van’s sheet metal (where heat can build up and shorten their lifespan) or drilling extra holes straight into your roof, a modular roof rack allows you to bolt rigid, glass-fronted solar panels directly to the crossbars.
Will a roof rack increase fuel consumption?
Yes, but the impact is minimal if designed well. An empty, low-profile aluminium rack does not affect the consumption much. However, the real drag comes from what you put on it. Strapping bulky items like storage boxes, spare tyres, or roof tents to the top can increase fuel consumption by 8% to 15% at motorway speeds.
Are roof racks worth fitting to a campervan?
Definitely! A roof rack is worth fitting if you need to free up cabin living space, carry bulky adventure gear, or mount off-grid essentials like solar panels, awnings, and lighting.
