Winter 2024
Vannon V2 Roof Rack
A low-profile aluminum roof rack developed from prototype through production.
Overview
Project scope
I supported the design and fabrication of a modular roof rack for Mercedes Sprinter vans while working at Vannon. The system was developed in CAD, prototyped on a large CNC router, formed, test-fit, and refined for repeatable production.
Challenge
Design problem
The rack needed a clean low-profile appearance, strong mounting points, efficient material use, and compatibility with different van layouts.
Solution
Engineering approach
The final design uses CNC-cut aluminum side rails, formed mounting tabs, and modular crossbars that simplify installation and allow accessories to be positioned as needed.
Build process
Project gallery
