We have a Grand Design. Anecdotal evidence says the early models were better built before GD was aquired by Winnebago and experienced explosive growth. But you'll be hard pressed to find a manufacturer with better service after the sale. There are stories about GD replacing walls on 4 year old trailers under a goodwill warranty.
The dealer makes or breaks your experience. Being told you need to leave your trailer for 2-3 months for warranty work is BS.
I don't know about your Expy. With 5 people you will probably be pushing your payload, rear axle, and maybe hitch ratings. Short of taking 2 vehicles many large families use a 1-ton passenger van.
