Earlier quoted context omitted.
Actually, the largest cost is building a whole new structure. With a fully reusable rocket (as SpaceX is going to use), the only costs are fuel and maintenance, which is more expensive than an airplane (~$50k per flight, IIRC), but negligible compared to the initial cost of designing and building the structure. Could you imagine if airplanes were single use? There would no way Southwest could achieve a 45-minute turn…
> With a fully reusable rocket (as SpaceX is going to use) This is the sort of thing where you need to be careful with what you infer, the the sort of thing that often causes engineers to be overconfident in performance and reliability estimates.In reality, they're doing some very initial experiments in vertical landing with a view towards exploring reusability. That is different to your implication that reusability…
The plan is full reusability, except for a few parts that are lost as each stage separates from the rest, and fuel. There is no plan B. http://www.transterrestrial.com/?p=27574
And re: testing, I misspoke. By "part" I didn't mean component, I meant to say "system" but had in mind testing each part of the mission and contingency plan (in addition to end-to-end tests). I, and the engineers at SpaceX, are aware that most failures come from interactions between systems. And by "extrapolate", I didn't mean extrapolate from one part to the entire system, but from N tests to the N+1th test (because when you test as you fly and fly as you test, the actual mission is just another test).
Also, you conflate 'safety' with 'complete system success.' Apollo 15 had a safe, successful reentry, despite the single parachute failure, because there was designed-in redundancy. You can expect similar from SpaceX.
But you are right in that assigning any sort of reliability number is rediculous. On my project, we have analyzed every possible failure scenario we can think of, and come up with contingency plans on top of contingency plans, until we get to the point where so many things would have to be wrong in order for our plan to be used that it's not worth the effort, and we would think on our feet at that point. But still, nobody has bothered putting out a percentage chance of mission success. And nobody has asked the launch vehicle for a percentage chance of correctly inserting us into our desired orbit.