This article seems worrisome....
High Tech in the '70's, Shuttles Feel Their Age
By JOHN SCHWARTZ
Published: July 25, 2005
CAPE CANAVERAL, Fla., July 24 - Like an increasingly creaky baby boomer who can still run a marathon, the space shuttle is a delicate organism that can do miraculous things. But as the Discovery prepares to lift off Tuesday morning on the first shuttle mission since the loss of the Columbia two and a half years ago, it is clearly feeling its age.
The launching is scheduled for 10:39 a.m. Tuesday, but the question of malfunctioning fuel level sensors is still hanging over the process....
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Age-related complaints abound. Workers have sweated over the shuttle's main engines, which endure some of the most pronounced stress of any component. Documents for the Discovery's flight readiness review in June showed that engineers had found and dealt with tiny cracks along seals in the main engines and ruptures in some of the engines' nozzle tubes.
In the solid rocket boosters, corroded bolts have been discovered in the motors' nozzle joints. Elsewhere, a leak was discovered in a flexible hose used to deliver oxygen to the crew before the launching of the shuttle Endeavour in 2002; corrosion was later found in similar hoses.
The flight readiness documents state that these issues and many more have been addressed and do not constitute a threat to flight. And agency officials have readily acknowledged the difficulties of maintaining a system with parts designed and created so long ago....Just last week, the agency's inspector general issued a report describing continuing problems with a kind of wiring used throughout the shuttles as a "safety risk."...
http://www.nytimes.com/2005/07/25/science/space/25shuttle.html?hp&ex=1122264000&en=441b5135b4d2dc83&ei=5094&partner=homepage