I've never really been happy with any of the deck solutions ive seen, and most of the DIY decks of just screwing a cedar plank down--um no. So i collaborated with a friend at Flagwerks
who i have worked on other projects with and he is good in CAD. We talked about my ideas, he threw in his etc and i think we came up with one **** of a nice roof top deck that works with modular racks (most use 80/20 cross bars), this one happens to be a Remora. 3/16" aluminum plate with a fold on edges for strength. This one also happens to be on a Sprinter, but modular roof racks all have the same concept. 200 lb man standing in the center of largest panel create less than 1/4" deflection. Before all the comments start flowing about why a roof top deck is needed, this was something my client wanted for ease of snow removal as first criteria. secondary was ease of loading and strapping down a kayak or paddle board (see aircraft/l track style tie down points), 3rd was a place to have a sunset cocktail. Also know form my past career working with photographers a lot, decks are super handy. so not everyone has same needs is what im saying.
Anyway, this can be applied to anyones build, until we see more sizes repeated across various roof configurations we are considering each one a custom consultation. of course next level would be powder coat for traction and corrosion resistance, but this client wanted it raw for now