There’s a WHAT in that box?



I grew up around airplanes. Got excited whenever dad’s new issue of FLYING magazine arrived.
Like so many other kids of the era, when the issue showed up with the new BD-5 splashed on the cover, my first thought was: “I have to have that airplane!”.

Growing up to be a semi-responsible adult, that thought slowly moved to the back corner of my brain, but kept its little spot on the shelf, never completely going away.

So when a partially-built one popped up for sale recently, I was intrigued.
Today, the back of my hangar looks like this:



As we were loading subassemblies and parts on the trailer, I was also building the plywood box to keep everything protected on the way home.

What I’ve learned:

-For all the advertising about how easy it is to build, there is a tremendous amount of fabrication to be done by the builder, especially compared to the RV-7.
Page one of the instructions:
“Thank you for purchasing a BD-5. A dump truck will be delivering a load of bauxite to your driveway. Start smelting aluminum”. Well, not quite….

-Building the kit according to the plans will be unairworthy.
Critical measurements are to be taken from the parts supplied. The subcontractor, however, did not cut the parts to the exact dimensions required. They assumed the builder would trim to final size, so taking measurements according to the plans are all off. The plans have no mention of trimming parts, or even list the proper dimensions.
The BD-5 must be assembled in a jig.
The first customer-built airplanes had a horrible safety record. Several crashed on their first flight.

-Like the RV series, a BD-5 built to the originally engineered configuration will result in a nice flying airplane, but any modifications will probably be detrimental.
If 60 horsepower is good, why not 100? Installing a heavier liquid-cooled engine requires adding lead weight in the nose. Instead of a 55 mph stall, it now stalls at 80. And the airplane’s structure uses the pilot’s knees as the crumple zone.

-Pilot reports of flying BD-5s universally praise the light controls, the excellent control harmony, and remark how easy it is to fly.

This particular airplane:

It has been through a few different owners. Some of the craftsmanship is really good. Some is merely airworthy. And in a few places, it’s: “you’ve got to be kidding”. There will definitely be a bunch of rivets drilled out, and new parts fabricated using proper tools. In a few places, assemblies were completed before earlier steps, which will create some difficulties going forward.

This airplane will have no upholstery. Instead of a padded seat, I will be sitting on a parachute.
Remember “using the pilot’s knees as the crumple zone”? If problems arise, and no suitable landing site is within range, the plan is to roll inverted, and pop the canopy and 5-point harness loose.

Let the fun (and frustration) begin….

Interesting project. Looking forward to watching the process.

I’ve been intrigued by them too but the build scared me compared to rag&tube. Please post build updates. Looking forward to seeing your progress.

I remember Richard Bach describing it as the only plane that was harder to take off than it was to land.

Good luck with the project! I hope to see it flying sooner rather than later.

My dad (builds/races cars ... limited? knowledge of airplanes) has been eyeing one of these. There was a used kit around somewhere for a few grand. He’s great at turning bauxite into machinery but I still wouldn’t take that to 5 AGL. Haha... I told him his first airplane build should be an RV or similar with a community of support and more standard components.

He’s got 2-3 seasons left .. then we’ll see what happens.

Everyone that I know who has flown one says it is a marvelous flying machine, but everyone that I know was flying a jet. I have never seen a piston-powered version that flies.

Is that the one that sat at an FBO at REID Hillview for years?

I think I've seen 2, both at OSH in probably '84 or '85.

My sentiments to a 't.'

Having built one airplane, it makes me tired just looking at that photo. May the force be with you...

I cant count how many unfinished BD5s I have run across over the years. I actually had someone call me with one that comes with an additional set of J wings just yesterday if anyone is interested.

I met Bob Bishop and Corky Fornof in the 70s when I was working line service. They put on one of the most memorable airshow routines that I have ever seen and were super nice guys.

I was driving south on US 77 from Nebraska some 10 years ago and saw one. A farmer had mounted it on a pole and was using it as a wind tee. Don't know if he was the original purchaser or not.

I remember that they had a pickup truck with an articulated arm extended in front with an airframe attached to it for pilot training. I heard they were very pitch sensitive and most pilots had PIO first flight.

I remember something that Chuck Yeager once said:

"If this thing had an ejection seat, I wouldn't be here!"

When the BD5 was first publicized I remember there was a LOT of buzz about it. They had a fly-in at Livermore for a flying demonstration and they had a test pilot give a demo. It was powered by a four cylinder auto engine (Honda I think) but I think that was the only example. Lots of kits were sold (my roommates Dad bought one). The piston power plant choice never did get worked out as far as I know.

The jet version seemed to be the only practical combination but it was too spendy for the backyard hobbyist.

Dan