and to repeat again, it is about cost, not about a big rocket
that was major issue with Shuttle, to much labor to make it re-flight with enormous cost.
SpaceX aim to reduce the Production cost of Starship/superheavy to $3 million !
with use of Steel they far step ahead in cost reduction, compare to expensive Al–Li alloys or Composite material.
But the major point is cost of Raptors engines and Starship Heat-shield
here lies the biggest challenge !

On Raptor they testing version 3 what has allot reduction in parts, but still high production cost !
about this Musk mention that 3D-printed metal parts are expensive.
Since 2021 they work on LEET or Engine 1337, it low cost version of Raptor that cost $300000/unit

other issue is the Heat-shield if this turn out to be labor expensive task to replace the 18500 tiles after each flight
its GAME OVER commercially for StarShip
It must stand several mission before it replaced totally.

This are biggest issue with Starship program for moment
 
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You certainly do not want a similar situation happening like what happened to Columbia where the Starship burns up in the atmosphere.
 
No, it wouldn't. Can't test easily, no easy change out, no reproducibility..
See below
Why do you want to throw away the baby with the bath water? You still don't get it. It is not just about building a very large rocket. It is about cost.
I didn't say throw it away--Ship 5 with the single downcomer would be sufficient for an expendable Starship anyway. An expendable design would cost less--be less of a headache though.

Perhaps lunar Starship could use a single downcomer and accumulators both to be extra safe. It could land then.

In the past, I championed the idea of "rocket-as-payload" with wet workshops.

Now it is "rocket as engine."

Your criticism about such a design (can't test easily, no easy change out, etc.) could just as easily apply to NASP, where the whole vehicle is an inlet.

Since Starship is designed for re-use--and since the stock Starship is designed to be recoved via chopsticks catching it just below the forward fins --you don't have to worry about landing it on the bottom--so the whole width of Starship's tail could be a super-wide nozzle.

Remember the concept where you had three SRBs connected by struts?

Have those reach up instead--attached to the sides of Starship just above the engine.

This gives more separation between the two stages. Instead of a hot-staging ring--just have curved panels that bear no real weight that blow apart at staging.

If NASP could have been all inlet--perhaps Starship can be the all-rocket equivalent of that--with injectors being all that needs changing out.

Having the whole lower part of Starship be a beefy nozzle lends itself to re-use.

That part can be swapped out if need be. They can take hot stage rings off, after all.

In the CSI STARBASE video, aluminum was called for on some lines.

At the New Materials thread, I posted a link to a phys.org article about aluminum that had better strength when cold.

Even if Elon doesn't want an all aluminum bird--he could at least use that for propellant lines.

On the subject of propellant lines if might be good to have as much plumbing being outside the rocket for EVA/refueling --and to limit leaking propellants into confined areas where you could have an explosion.

With as much plumbing on the exterior of the rocket that you can get away with--leaked propellants just goes into the vacuum. Tesla valve fuel lines may limit Pogo as well.
 
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Your criticism about such a design (can't test easily, no easy change out, etc.) could just as easily apply to NASP, where the whole vehicle is an inlet.
wrong.
A. NASP could go through wind tunnel testing
b. Sub scale testing (see X-43)
c. Incremental testing (increase speed in step)
d. A, b & c not feasible with a rocket
e. where is the working NASP as an example?
 
1. Since Starship is designed for re-use--and since the stock Starship is designed to be recoved via chopsticks catching it just below the forward fins --you don't have to worry about landing it on the bottom--so the whole width of Starship's tail could be a super-wide nozzle.

2. Remember the concept where you had three SRBs connected by struts?

3 Have those reach up instead--attached to the sides of Starship just above the engine.

This gives more separation between the two stages. Instead of a hot-staging ring--just have curved panels that bear no real weight that blow apart at staging.

4. If NASP could have been all inlet--perhaps Starship can be the all-rocket equivalent of that--with injectors being all that needs changing out.

Having the whole lower part of Starship be a beefy nozzle lends itself to re-use.

That part can be swapped out if need be. They can take hot stage rings off, after all.

In the CSI STARBASE video, aluminum was called for on some lines.

At the New Materials thread, I posted a link to a phys.org article about aluminum that had better strength when cold.

Even if Elon doesn't want an all aluminum bird--he could at least use that for propellant lines.

6. On the subject of propellant lines if might be good to have as much plumbing being outside the rocket for EVA/refueling --and to limit leaking propellants into confined areas where you could have an explosion.

7.With as much plumbing on the exterior of the rocket that you can get away with--leaked propellants just goes into the vacuum. Tesla valve fuel lines may limit Pogo as well.
1. Fails right there. No throttle control, no attitude control
2. A kludge and not good engineering.
3. not feasible,
4. not workable, see F-1 issues
5. Aluminum is not good for cryogenic fluids
6. there is nothing that EVA can do with these propellants.
7. Plumbing on the exterior is a bad idea. Costs are higher, more pressure drop, more heating, more complicated. valves don't fix pogo
 
I didn't say throw it away--Ship 5 with the single downcomer would be sufficient for an expendable Starship anyway. An expendable design would cost less--be less of a headache though.
You are throwing it away. Major redesign. The current design only requires tweaking and not major changes.
 
SAR picture of Robert road SpaceX facility
it show the Gigabay foundation and Launch platform (as solid blob in lower center of Picture)
Musk tweede that Launch is Next Week from 19 to 25 May
precede by company talk by Musk at Starbase about "Mars Game Play" livestream on X

Gq5-3R_bwAAdf13
 

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