[andyl]

I used 1/2 luan ply finished with non-skid deck paint. Light, cheap, strong enough. Easy to tweak, easy to repair.

 

[andyl]

How's it holding up?

So far so good! Deck made it easy to shovel after a recent snow storm.

We've dinged the deck panels a couple times. Easy repair just remove the panel, sand and repaint.

more details on how you mounted it to your crossbars

On the larger panels, we added finger holes for easier handling. Sometimes we use a pull strap to raise the panels onto the roof. Be careful the non-skid is like sandpaper and it scratches. Might be smart to put the non-skid only on the top surface.

The narrow slots on the crossbars require somewhat precise alignment. I made the bolt-down holes oversized, used drop-in t-nuts with fender washers. There's enough slop in the system such that the bolt-down holes don't require perfect alignment with the crossbar slots.

The t-nuts are Amazon.

Amazon.com: 80/20 Inc, 14162, 10, 25 Series 10-32 Standard Drop in T-Nut (25 Pack) : Industrial & Scientific

Buy 80/20 Inc, 14162, 10, 25 Series 10-32 Standard Drop in T-Nut (25 Pack): Strut-Channel Nuts - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

Are you using 80/20 crossbars?

Yes I use the crossbars that came with the FlatLine rack. Purchased two extra rails from FlatLine. Also bought a couple of short bars and L-bracket connectors from 8020 to reinforce the decking on the sides of the roof fan.

In front of the fan, there is roughly a 15-inch span between the crossbars. The panels flex under bodyweight, but give adequate support. I do not notice vibration or sound at highway speeds. The gaps between the panels have been useful as handholds.

 

[andyl]

Where was the photo taken with all the snow on it? Tahoe?

Yes Tahoe they say we had 200+ inches of snow in Dec.

I bet the snow on the van in that photo weighed 500 lbs.