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Who cares? Even if they never solve the flap issue, the cost of bolting on new flaps every flight is minimal.

That's like bolting new wings on a 777 after every flight. It's going to cost a LOT and you won't be able to just load up fuel/passengers and take off again.

I'm sure SpaceX will eventually fix the problem. They are well funded, the materials exist, and they have amazing engineers. They just haven't reached that point yet.

When the current industry standard is that the whole 777 is replaced every flight, that's one hell of an improvement.

That isn't the industry standard anymore thanks to SpaceX. Starship isn't competing with Saturn 9 and the Space Shuttle, it is competing with Falcon Heavy. If the second stage cannot be re-used then you may as well launch a much cheaper second stage that isn't rated for re-entry like Dragon.

'Cost a LOT' is relative though.

Expensive compared to a 777 flight? Sure. Expensive compared to every other moon capable rocket? No.

But is it going to be cheaper than Falcon Heavy?

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