If I were you and were serious about this (which I think you are) I'd go to the factory in Jackson Center Ohio and watch them put these trailers together and see the components they use.
I'd also talk to engineering.
I know the smell you speak of, but I think it may "vary" between models. Our CCD28 has different materials in it than (say) a Classic, but in any event the tours Airstream does are very open to discussion.
I’m revisiting this old thread because of the recent issues with formaldehyde in the news. When I bought a new Safari 10-years ago, it had a strong formaldehyde smell that took about 2-3 years to dissipate. I found it irritating and probably unhealthy.
I wonder if the newer trailers have the same smell.
Maybe the factory changed their source of fiberboards and glue.
Any owners of new Airstreams want to comment?
I am here on the Airstream site because I recently attended an RV show and out of the dozens of units I entered, the Airstreams were the only ones that did not smell of plastics and adhesives. These AS units were 2014-2015 models with no coatings on the interior aluminum skin.
I am not allergic to the organic plastic and adhesives materials or smells - I just liked the cleanliness of the AS interior with the exposed aluminum. The absence of odor was just a side benefit.
Some of the RV units I entered smelled so strongly of plastics and adhesives it was overpowering. Like I said, I'm not sensitive to those materials but when I notice it - it's bad. Had my wife been along she would have rejected every RV but AS based on smell alone.
I have asthma. We bought our Safari Sport new in 2007. The saleman had aired it out for several days before we came up to look at it. Never had a problem.
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