Pluto wasn't unworkable. In fact, the basic design is quite solid and should work just fine. (NASA is looking at that engine for a planetary atmospheric probe, for example)
'Can't be test flown' is pretty unworkable for an operational weapons system, in my book.
Those salted nukes were proposals mostly from Los Alamos, RAND corp., DAPRA
Yep, a bunch of R&D folks - the operators wanted nothing to do with them. Ditto the 'doomsday weapons' - they were never anything more than 'this is theoretically possible but stupid, let's keep an eye out for the Bad Guys doing it'.
The clean bomb
is an interesting idea, and the idea that it would make war too easy is the kind of nonsense I'm all for criticising McNamara over. I don't think reducing the radiation hazard would make killing tens of millions significantly more appealing to anyone who's fit to lead.
1. On a circular hatch less than 3 foot across. That is easy, especially with the shape, the ease of reinforcement and minimal seal length.
2. Double the pressure, increase the hatch area (3-4 time larger), longer and complex seal path.
5 psia increase is 5000 lb more force on the shuttle hatch equivalent, 15,000 - 20,000lb on the SR-71 canopy.
Also, all the penetrations for wiring and controls have to be stronger.
A big deal, but an engineering problem, not one of fundamental mechanics. Doubling the pressure differential on the penetrations is easy. Thickening the pressure vessel is easy.
The cockpit seals are the hardest part, but still not fundamentally different. Broadly speaking - double the number of catches, add more seal material. The kind of pressure differential we're talking about is actually slightly
less than that used on Concorde, which maintained 10.7psi with fare-paying civilians on board.
You could even compromise and run a ~7 psi atmosphere. That's about as low as you can go without the need to prebreathe. I suspect it isn't coincidence that that's also what a 5 psi differential gets you at ~50,000 feet, where US regulations (based on 5 psi differential) require a pressure suit.
I'm not claiming it's a trivial change, but it's not one that should be beyond a competent design team. There'll be an increase in weight, but a slightly heavier aircraft that can actually perform the mission is worthwhile.