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Philhyde,
The smell of the first one we had (a 2002) model wreaked of the formaldehyde smell. It took us a good 6 months before the smell got weak enough for us stay in it. And even then it took about a year before it was truly liveable.
Our new 2012 has little to no out gas smells. There is just a hint of something but even it is not too strong. Absolutely nothing like our old rig. They really have done a fantastic job of taking out the offending gases. At least that has been our experience. Dennis and Mary Kay
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