As a matter of fact Phatkd, my last trip up the ladder last week down in Red Bluff CA resulted in one busted rung while I was headed up to sweep the slid toppers before rolling them in for the winter. Regarding the idea of having a custom-build ladder welded up, that sounds like a good idea, in so much as the OE parts simply aren't designed to actually use as a climbing ladder. They do look nice hanging out there on the stern, but after a couple trips up and down, it quickly becomes apparent that the ladder is for looks, not for practical use. It seems that if I were going to the extent of having one built, I would probably have it constructed of round stainless tubing, maybe up to even 40-ga pipe, rather than aluminum. My thought process here is that the stainless assembly might be easier to polish, and to resist corroding easier than aluminum. I suppose that if there is not so much wet environment exposure to the aluminum, it could remain looking okay once polished. In designing a new custom built ladder, it seems that there should be a little more consideration given as to how the weight is supported from the top. The OE ladder design springs so much due to the poor design/material choice, that it simply can't support much more than my 10-year old grand-daughter. Since keeping a 5'er clean around the upper edges, all the way around the RV, it nearly demands that you carry a ladder to reach the top edges, meaning, you just about have to carry a 14+ foot ladder anyway. If it weren't for needing to climb up all the way around the RV, I would consider a custom built ladder also. Since it seems like I end up standing on the top platform of my 5-foot stepladder, maybe I would be smarter saving up for a Little Giant Super Ladder like many others claim to carry. I think your idea is reasonable, and no question about it; much safer. gebills.
folks won't even think about using the OEM ladder. I have a 6ft step that unfolds and extends to 11 ft and I can access the roof by going up the rear of the main slide.