mlts22 wrote:
I've wondered why RV makers don't just use either one large piece of aluminum, or perhaps multiple pieces TIG welded together, something that the edges can be folded down the sides of the roof for a few inches.
Couple this with Rhino Linings or Dave's Permanent Coatings epoxy roof coating that flexes/stretches, and one would have a roof that would outlast most people and need no upkeep other than checking for tears due to branches.
Answer: Price, EPDM and plywood is a lot cheaper than sheet aluminum. Also, labor costs, you would need more skilled labor(welders).
If the PO's of my Starcraft had kept up with sealing the roof edges, it would have endured the 40 years until I got ahold of it with no damage. After breaking out the bad parts, I could see the "band aids" that were applied without fixing the root causes of water damage, i.e. loss of seal at the roof edges.
I've got no disrespect for Airstream, a lot of their older rigs are still being used. I actually have my eye on a single axle Airstream from the '50's that sits parked in a guys back yard. He has had it parked and used it as a storage shed for Harley parts. I guess Airstream and HarleyD are made for each other, lol.