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160 - "I seem to vaguely recall some discussion, years ago, of replacing the current crew cabin configuration on the orbiters with an integral, reentry-survivable pod. If an emergency arose during launch, it could be ejected under its own power and soft-land. It could also re-enter the atmosphere from orbit if the orbiter failed the re-entry burn.

Do you recall why that option was never utilized? Cost? Technical hurdles?"

There really is no way to survive more than very minor problems. The original shuttle design they adopted can't be modified effectively.

Here is what became of that idea.

They changed the crew door, made it larger, and put explosive bolts on it. they designed a pole, about 10 feet long, for the astronauts to line up, attach pole to the doorway, and one at a time, slide down this pole and jump out in their space suits with parachutes, all the while hurtling to earth in an emergency.

(And as silly as that sounds, it is no joke - that is the proposal which was finally adopted - though I don't know if it was ever implemented) I saw the tape demonstrating how it was to be used.

You probably have never heard of it, justifiably so. But we used to play it as part of our 'training' time when we wanted a good laugh.