I'm seeing 10 GA, sides and top, but maybe that's not correct. That was the insert. I assume the insert and free-stander would be the same box but maybe not? I guess I'd be less concerned about thinner steel in the top in an insert, since the blower would keep top temps lower over all.
When I heard a loud pop, and thought I had possibly broken a weld on the Buck 91, I examined the stove and found some creosote erosion when I removed some firebricks. That stove was under ten years old. The "pop" was apparently a side flexing.
I don't know how you, much less an owner, would even be aware of such a problem unless the bricks were removed? Some guys in that thread said they were going to look behind their bricks, but I didn't see any subsequent posts, except for one guy that said he found some deep pitting. Maybe you would never know, even if it rusted through, if there wasn't a major performance issue to tip you off. I don't know when BK sales took off in earnest but with more of them in the field nationwide now, any issues should come to the fore as time passes.
When I saw the creo erosion in the Buck I said, 'At least it's gotta eat through a quarter inch..that will take a while.' If I'm getting less steel, I'd like to see a correspondingly lower price, but that's just me.
I'm curious to know more about the "differences in expansion rates" that you mentioned? Is that from running the stove too hard when bringing it up to temp, or what?
Back to the OP's question, I don't think creo erosion would be an issue with a non-cat since they don't smolder-burn like a cat might.
It's not always an option but I hope he can see both stoves in person to answer the steel question, and compare other features firsthand.