So yeah, spoilers about Rogue One. You've been warned.
Ok so, I was listening to the O66 Podcast about R1 recently, and it dawned on me, after they talked about how it was a brilliant move by R1 to "fix a glaring plothole that fans have been bitching about for decades".
At first I was like "yeah, that's right, it does tidy that up" and then I actually thought about it.
"No, there is no freaking plot hole. People build massive things that they think are perfect, and later find they've got a massive design flaw in them, that they only learn about after the thing sinks or blows up."
Remember the Titanic anyone? The Unsinkable Ship? Spoilers but, it sunk on it's first voyage. Sunk in such a spectacular way too, and they didn't bother with enough ships for all the crew, so massive deaths. Oops, yeah...probably should've considered that a bit more in the design stage.
The Hindenburg. Hey yeah! Let's make a massive blimp and fill it with a highly volatile and flammable gas! I'm sure NOTHING could go wrong that might cause the entire thing to.....burst into flames, killing everyone on board in a horrific inferno, caught on film for the world to see...a testament to bad design....oops.
Hey yeah! This Death Star is the "Ultimate Power in the Galaxy!", there is no way that we need to worry about something as petty as an exhaust port, that might be vulnerable to a snub fighter! Like that will ever happen! Oops.
I dunno I just, seems like a pretty typical, and familiar pattern in human design if you ask me.
As to Return of the Jedi, well, the thing wasn't completed. The external shell was clearly unfinished, allowing plenty of avenues of entry. The Emperor didn't care about that, he just made sure the guns were working properly, the rest of it? Pssh, who cares?! My plan is fool proof! They will walk into my trap! Everything is as I have foreseen it! Hahahahaahahahahaaaaaaaaaaaaaaaaa.......You think anyone was going to second guess the Emperor? With Vader there? Heck no! They were like "Oh my god please don't kill me for passing gas in a way that upset you! Just build the thing like they said! I don't care about design flaws! Do you have ANY idea what the officer attrition rate is in this military?!?! Well I DO!! And I'm not going to get choked out via vid screen by telling Vader what your concerns are! Just do what they say or I'll shoot you myself!
So yeah, there is no plothole that needed patching, fans are just too anal and nitpicky about everything, and had nothing better to do for 30 years than to try and pick apart every frame of those films and try and find flaws.