spacehawk

If you're looking for more detail on David Clark suits (they made all of the suits you listed), the book made in conjunction with NASA is a great read: https://www.nasa.gov/pdf/683215main_DressingAltitude-ebook.pdf.

Have you tried going to a local machine shop? If I was to do this personally, I would bolt through the 0.010" sheet into a piece of aluminum with known indexed holes where tiles are not to be cut. If you wanted more control, double sided tape from 3M is great. The CNC would need to be outfitted with a really small diameter tool (easy to order), and then run from there. That would remove the 15" limit as most CNCs have travel measured in feet. Just an idea! Also, most shops order material for specific jobs anyway so stock is not a big deal.

Check engineering at the door, but a lot of it is visually comparable. I view it in the same vein as The Right Stuff. Not accurate, but captured the feelings of the times. Things like the orbit altitude and inclination of Hubble vs. ISS are off. Spacesuit wise, lots wrong, but I can only see that because I worked on the real ones. Every astronaut I know that has gone to see it has said similar things. With all of that said, it's my favorite movie this year.

What shuttle will would be using as the base? Columbia has a different strake/chin than the other orbiters. Whatever the answer, put me down for a set.