I know this is a space topic but this "backyard mechanic" approach doesn't belong on the same page as Tom's launch system.

The possibility of Thermal Protection System tiles "falling off the shuttle or another vehicle like Tom's just bugs the heck out of me.

What are the chances of mechanical attachment? I thought of one simple way but I don't know how sound an idea it is.

Rob's "bolt 'em down" approach

Since the tiles are highly machinable we should be able to "core" down through the face of the tile to about 3/4 of an inch above the attachment surface(Many of the Shuttle tiles are 1/2 inch thick). Next drill a bolthole through the remaining 3/4-inch of tile. Using a bolt and thrust washer - bolt the through the skin and a thrust plate on the interior side of the skin to a weld nut attached to the thrust plate.

Key to the design is bushing the bolthole. If the bushing were made to be .011 taller than the 3/4 section of tile it passes through, then this would allow for .008 of RTV silicone adhesive used to bond the tile and .003 of additional clearance. The bolt could not be over- torqued, stressing and deforming the tile. In effect -a zero force fit. Actually juts a redundancy to the adhesive process.

To protect the bolt a “replacement core” with very small tolerances (.006 diametric?) could be manufactured from tile stock with a recess for the head of the bolt. It could be "glued back" in place over the assembly.

(Hey, it was either Word or Paint)

Regards