Well Salmontackler, the actual vinyl itself may be made by them, but they're assembled by Aire itself (unless they're lying on their brochures). Outcast uses a less durable material, while Aire actually uses a stronger type for the hull. It's like apples and oranges on that statement, you can buy two cat frames, but they materials may come from same galvanized steel plant, but both frames are not the same. It's all in construction. Actually your top of the line Outcasts are made in conjunction with Aire, BUT....the frames suck. They only have two support crossbars that are maybe at most 1 inch diameter aluminum. They're frame isn't wide enough so less stable side to side. I've owned them so I know them (I've almost had my outcast buckle on boulder drop on the Sky and know people who have had it happen to) So, I never said it was the pontoons, I said it was the boat themselves. I never said it was a bad boat, just not suited for whitewater. You look at a 12ft outcast, and they're the SAME width as their smaller 8ft boats. You have no room and not very stable. Plus their pontoons never really get any bigger diameter when they get longer. Exponentially they should expand widthwise if you expand lengthwise. So, you see, if they're supposedly the same boat, why would an 8ft outcast only carry 250lbs and an 8 ft Aire handle over 600lbs? It's not in material, it's how they're made.
Ok, thickline, if you can do it, go for the 16fter. They're not as bad as you think. I use mine on the Nooch on low water flows of summer and have never had a problem with it. Just make sure you have a frame that fits the boat. I'd seriously say stay away from the outcasts. They're good for one man slow river/lake boats, but not for whitewater. If you plan to do any serious 3/4, you want actual whitewater pontoons (ie Aire, Maravia, Wing, etc). But, as I said before, go with what you want. I'd go with a cat if I were you, but go to that homepage I told you about (it's the NWRA northwest rafters association) They have some good deals on true whitewater boats. If you were to buy a boat, I'd go with the Puma, not the outcast (as much as I don't like rafts). Pumas are at least whitewater used safely. But seriously, look around a bit. You can get a decent deal on a used cat. You'd be suprised how well a 16fter will handle and what type of areas you can float with it. Good luck.....
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you haven't lived til you've rowed a cataraft. Friends don't let friends run Outcasts.