Here's where I'm at:
I pulled everything apart. Sure enough, there's a very tiny tear in the skin, under the hole in the black stern cover. I ordered a Tear Aid Type B patch kit (actually two of 'em), I'll get it fixed in a few days.
1) Those black bow and stern "bumpers", whatever, should be harder plastic, or tougher Hypalon. I'm not impressed at all with them, and they are supposed to protect the highest wear areas on the hull...
2) It doesn't look like it'll be too hard to fix. However, if AE is a fan of Tear Aid, perhaps they should include some in the patch kit? Just a thought...
3) I think once I get it patched, I'm going to cover the bow and stern sections with "Gorilla Tape", a very tough kind of duct tape. It would act as a "sacrificial" layer, to protect the hull, and is cheap and easy to replace when needed.
4) Otherwise, I'm very impressed. I have a Klepper and a Long Haul, both folding kayaks. I wanted something lighter and faster to prep for a quick afternoon paddle on a local lake. The Expedition handles wonderfully, tracks very well, is absolutely stable even in choppy water, and really very comfortable.
5) It occured to me that the floor could have other uses; as a float toy for goofing around in the water. Or as an air mattress, for unplanned overnight camping. I'll give it a try as both as soon as I can.
6) I pumped up the main tubes and set it outside to dry the day after my first trip. Even after being outside most of the day, when I noticed the tear in the stern piece, I pulled everything apart, and there was still a good amount of moisture trapped between the main chamber and outer skin. I plan on seperating the skin, floor, and main chamber for drying and storage, to be sure all the water is out. Just my 2 cents.
7) For the money, this is a really nice kayak. Just be sure you don't leave shore w/o a pump, and a good patch kit. Including some Tear Aid Type B (not included)