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Since were using an inline SDV, we can load all the equipment needed to outfit the tank in the cargo portion. After second stage separation the tank uses the leftover fuel to achieve the best orbit it can. The cargo portion then rendezvous with the tank, and meets with a semi-permanently manned construction platform, which really doesn't need to be any more complicated than a TransHAB with a SSME and a pair of CanadaArms.

Depending on how long it takes to complete a tank, I'd guess we could finish 4 per year, give or take.

If you estimate a billion for your construction platform, a crew of three delivered via CEV for a 6 month stint (launched on an SRB, $75 million, guessamate $300M for the reusable CEV), 2-3 resupply CEVs($200m CEV and $75m for SRB) and a half billion per SDV launch, it's far more affordable than waiting for asteroid or lunar materials, especially considering that the tanks could play a critical role in getting such an operation up and running.

If you add that up...
Year One
Orbital Construction Platform (SSME + TransHAB + Robotic Arms ~ $1-2Billion
2 Crewed CEV Launches per year ~ $75M SRB Launcher* + 2 $300M Crewed CEVs +$10m CEV Recovery and Checkout= $760M
3 Resupply CEVs ~ $75M SRB Launcher + 2 $200M Resupply CEVs + $10M Recovery and Checkout = $620M
4 SDV Launches with all Cargo needed to outfit it ~ 4 * 1/2 to 1  Billion per launch = $2-4Billion
Total ~ $7.5 Billion
Year 2
2 Crewed CEV Launches per year ~ $75M SRB Launcher = $150M
3 Resupply CEVs ~ $75M SRB Launcher = $225M
4 SDV Launches with all Cargo needed to outfit it ~ 4 * 1/2 to 1  Billion per launch = $2-4Billion
Total ~ $4.5 Billion
*Conservative estimate, anyone know how much it really cost to recover and refuel an SRB?

Now that sounds like a lot. But in a lot less time and with a lot less money we could put the ISS to shame. In other missions we could put together the pieces to one good sized permanent Moon or Mars base in a couple years, and fantastic Mars ship with a couple of extra components. We are probably going to visit several lunar sites per year in the 2020-2025 range. If after a couple years of that we pause and pick a few sites to build permanent bases on, given a few years at this tempo we could finish them by 2035, have the infrastructure in place to immediately and seamlessly start building a Mars ship, and still have the money to keep the Lunar bases manned.

How much of this stuff is going to reenter after a while any way?

Start making things that don't pollute, and the bulk of the problem will probably solve itself.

Can't be all that much worst than if a psychopath gets a hold of a fork.

Sounds like the http://www.spaceislandgroup.com/home.html]Space Island Groups plans.

The use of ET tanks, be they from the Shuttle, or SDV, arr probably the best way to go about it. The pros and cons have been well hashed out over the years, and solutions have at least been suggested.

But theres no doubt that long term variable gravity reasearch needs to be done, and not just on humans. The key to producing self sufficent ecosystems away from Earth is getting critters to adapt new environments. That means 1g, 1/3g and 1/6g at least, all at once. A forth option would be useful as well.

As for the engineering, I'm not sure that fancy magnets are needed, unless your referring to wheels moved via electric motors.

Something this big should probably powered with reactors. Otherwise the size of solar panels, along with the massive weight of the station itself, it will be extremely difficult to shift the station to avoid space junk. The ion engines will probably need to be running almost constantly.

A shuttle bay would require a lot of cutting and welding, and the infrastructure needed to hold the pieces in place would be extensive.

I've been pondering the feasability of a bullet shaped spaceplane (think a much smaller version of that Lochked CEV thats been floating around) launched on a Pegasus-like booster that can send a refridgerator sized, 1-2 ton piece of cargo, or a single astronaut to a space station. On reentery wings pop out and it glides down, possibly on landing gear or skids.

The advantage is the boosters could be popped out like cruise missiles, and the thing would be so small that reprocessing the thing would take no time at all.  It could rush suppies and workers to a station, and since its dropped off the wing of a B-52, or a White Knight, launching several at a time would be affordable, and it could launch and return experiment quickly and cheaply.

A single HLV can send up dozens of single use heat shields and parachute packages. These are attached at whatever station is in LEO at the time. Then we just aim them at a desert.

What? A "simple" mag lev isn't good enough?

Imagine the speeds that could be reached in the thin Martian atmosphere.

The Chinese can't build SNBMs in the volume needed to land a knock out blow. We can assign two SSNs for every one they have.

That joke is lamer than FDR's legs. :;):

People don't seem to understand that well never be able to do anything serious in space without LEO infrastructure. We'll never be able to send any more than expendable toys to the Moon, nor anything but Apollo like missions to Mars without breaking the bank on massive launchers.

LEO construction is unavoidable.

The whole point of the SDV is to use the existing set up.

If were going to rebuild the pad and assembly buildings, it will lead to sticker stock.

All they needed to do was make sure crap didn't fall off the tank.

The rest is just gravy.