More bad weather was forecast for Sunday and for the rest of the weekend.
Storm clouds moved in and out of the launch zone throughout the morning and early afternoon. As the countdown held at the nine-minute mark, it became clear the weather would not cooperate, and launch director Mike Leinbach announced a one-day delay.
"We're not going to make it today," Leinbach said. "It's not a good day to launch the shuttle. So we're going to try again tomorrow."
The seven astronauts aboard the fueled spaceship immediately began backing out of their launch procedures. "It wasn't our time today, and we'll launch when we're ready and hopefully, tomorrow will look better," shuttle commander Steven Lindsey replied.
Dressed in their neon orange spacesuits, the astronauts had already been strapped into their seats and were ready to go.
It was a disappointment not only for NASA – the space agency last flew the shuttle last July and was eager to get flights to the international space station back on track – but also for all the guests. Vice President Cheney flew in for the launch, as did several members of Congress.
"Technically the weather was ok for launch, but it had been changing rapidly, and the time was running out," former astronaut Jim Voss told CBS News correspondent Peter King. "So the launch team made the conservative – and the correct – decision to wait for another day."
A last-minute technical problem had popped up Saturday morning, with the failure of a heater used to keep propellant from freezing in a firing thruster, but NASA officials were going to launch if the weather held. The thruster isn't used during launch, but it can control the shuttle's position in space and during a rendezvous with the international space station.
"It's not a show-stopper, in terms of rendezvous," said NASA spokesman Kyle Herring. "You can manage it."
The countdown proceeded as normal, and NASA was unsure what effect it would have on the launch. Space agency managers have said they want all four thrusters working properly.
The Discovery flight will test NASA Administrator Michael Griffin's decision to go ahead with the mission despite the concerns of two top agency managers who fear foam flying off the fuel tank might harm the space shuttle.
Bryan O'Connor, the space agency's chief safety officer, and chief engineer Christopher Scolese recommended at a flight readiness review meeting two weeks ago that the shuttle not fly until further design changes are made to 34 areas on the fuel tank known as ice-frost ramps. These wedge-shaped brackets run up and down the tank holding in place pressurization lines. Foam insulation is used to prevent ice from building up on the tank when it is filled with supercold fuel. Small pieces of foam have snapped off during previous launches.
O'Connor and Scolese agreed with Griffin's rationale that the risk was only to the shuttle and not the crew since the astronauts could take refuge in the international space station until a rescue vehicle is sent up, so they didn't appeal Griffin's decision.
"First of all, it's not a democracy. We don't take a vote. We don't need 100 percent of the people to say it's OK," astronaut Scott Kelly, whose identical twin, Mark, is Discovery's pilot, said of Griffin's decision. "He made the decision and I think it's the right decision to proceed with the launch."
Astronaut Stephen Robinson, who was part of last year's crew that made the first return to flight since Columbia disintegrated in 2003, said he was encouraged that the biggest technical debate was focused on the ice-frost ramps.
"If we're down to worrying about something like an ice-frost ramp, we must be doing a lot of things right," Robinson said. "There are much bigger things to worry about."
NASA engineers redesigned the external fuel tank after the Columbia accident, and again after a 1-pound piece of foam insulation came off the tank during Robinson's mission last year. In the most recent change, more than 35 pounds of foam have been removed in what NASA describes as the biggest aerodynamic change ever made to the shuttle's launch system. NASA tried other design changes to the ice-frost ramps, such as removing foam, but they didn't hold up well in wind tunnel tests.
Discovery's seven-member crew will test shuttle inspection and repair techniques, bring supplies and equipment to the international space station and deliver the European Space Agency's Thomas Reiter for a six-month stay aboard the orbiting outpost.
Astronauts Piers Sellers and Mike Fossum will make two spacewalks and possibly a third, which would add a day to what is planned to be a 12-day mission. The crew also includes commander Steve Lindsey and mission specialists Lisa Nowak and Stephanie Wilson.