I'm a drafter/designer who has worked with engineers for years and also designed my own fair share of parts...I'd say it's the liability issue. Overengineer something and you won't have to worry about it failing. Which in a lot of ways is good (safety and reliability), but it can also make maintenance a nightmare (as you've found) and drive up costs.
A former company I worked at designed (amongst other things) I-beam constructed baseplates ('skids'). A long time ago, an engineer had written a design guide (rulebook) for these skids such that the skids always were overengineered, and were much stronger than they needed to be. The main reason was so that dumb drafters like me could, by using the design guide, design a skid without an engineer having to approve it. It was mostly for lifting of the skids, so that there was a 4x safety factor. Hiring 10 drafters was a lot cheaper than hiring 10 engineers to design the same thing, even if you used more material.
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Today's Featured Article - New Life for an Old Allis - by Tyler Woods. My friend Jon, has an old '39 Allis Chalmers B. He thought it a marginal tractor that had long since served its time. She smoked terribly and never had much power but he couldn't afford another so he was limping along with what he had. Jon's Allis has a small front loader and though it doesn't carry much, it serves his needs. It was the hard starting and low power that made him think it was time to replace the old girl. Jon called me to help him discover why his tractor wouldn't start
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