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An experienced designer with more freedom to act might have realised that there was just too much optimism in the Ares I concept: that a shuttle SRB was simply too small as a first stage for a rocket carrying the relatively heavy Orion spacecraft.
Sometimes people wonder why aeroplanes are so cheap and rockets are so expensive. Even the most superficial comparison shows one obvious difference: aeroplane engines use outside air to burn their fuel, while rockets have to carry their own oxidisers along.
Historically, the U.S.'s big launchers fly seldom enough that their costs are dominated by annual upkeep of facilities and staff, not by the actual cost of each launch. The expensive part is maintaining the launch capability, not actually conducting launches.
Sometimes a malfunctioning test setup actually gives the tested system a chance to show what it can do in an unrehearsed emergency. During a test of an Apollo escape system in the 1960s, the escape system successfully got the capsule clear of a malfunctioning test rocket.
Trying to build a spaceship by making an aeroplane fly faster and higher is like trying to build an aeroplane by making locomotives faster and lighter - with a lot of effort, perhaps you could get something that more or less works, but it really isn't the right way to proceed.