Why not just create a cradle made out of lightweight materials
(fiberglass would work) that sits detween the shuttle and the tank. 
That would deflect 90% of the debris without adding more than a few
hunder pounds of weight.

This is of course assuming that the foam/ice fall is in fact the
culprit.

Joe Latrell

On Mon, 2003-02-03 at 13:38, Bruce Moomaw wrote:
> 
> http://www.cnn.com/2003/TECH/space/02/03/sprj.colu.shuttle/index.html
> 
> http://www.msnbc.com/news/867336.asp?0si
> 
> The foam fragment is now officially the prime suspect in the disaster --
> NASA's engineers concluded during the flight that it could have caused
> damage ranging from removal of a single tile to removal of tiles "over an
> area of 7 by 30 inches", but that this probably would not have led to a
> burnthrough.  It now starts to look as though the fragment actually hit near
> the seam of a wheelwell door -- one of the most vulnerable spots on the
> Shuttle -- so that the tile gap did the fatal damage that was considered
> statistically unlikely by those engineers.  (A whole series of observers all
> over California -- including a whole group of Cal Tech scientists -- now
> consistently report seeing several small fiery objects fall off the Shuttle
> during reentry, followed by a much bigger object.)
> 
> But this hardly makes it a fantastically unlikely freak
> accident --significant tile damage on Shuttles as a result of debris (both
> foam and ice) falling off the external tank occurs regularly.  (One engineer
> told "60 Minutes" last night that there have been flights in which, on
> return, "half the tiles on the vehicle were damaged".)  It now looks very
> much as though NASA applied the same reasoning on tile damage which (as
> Richard Feynman pointed out) they were applying to O-ring damage before
> Challenger: we've gotten away with it so far, so let's keep flying without
> any expensive modifications until we run out of luck, and only then run back
> to Congress with our begging bowl...
> 
> And -- even if we do solidly nail this down as the cause -- the
> modifications needed to correct it will be difficult.  Either we have to
> find a way to ensure that no debris -- either foam or ice -- falls off the
> external tank during launch, or we have to find a way to greatly harden the
> Shuttle's tiles.  Either way, we're looking at a mandatory program delay
> resembling that after the Challenger disaster, at a time when the Station
> needs constant manned maintenance.
> 
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