Development and Design
Dr. Bergon F. Brokaw, a former U.S. Navy fighter pilot from the 1940s and 1950s, embarked on designing the BJ-520 Bullet around 1966 with assistance from Ernest R. Jones. Brokaw's vision was to create a two-seat sports airplane with fighter-like performance characteristics, incorporating a rear seat for his wife "Buddy" and aerobatic capabilities. The ambitious project required six to seven years of development, reflecting the complexity of achieving high-speed performance in a homebuilt aircraft.
The prototype underwent significant evolution during its development. After the initial flight in October 1972, Brokaw recognized the need for major improvements and conducted a comprehensive redesign in 1976. The aircraft resumed flight testing in 1977 under its new designation as the "Bullet," incorporating lessons learned from the earlier configuration.
Engine Evolution and Performance
The BJ-520's powerplant configuration changed multiple times throughout its operational life, reflecting Brokaw's pursuit of optimal performance. Initially equipped with a Continental TSIO-520B turbocharged six-cylinder piston engine producing 310 horsepower, the aircraft later received a Lycoming TSIO-541-E1A4 turbocharged engine generating 380 horsepower. The designation "520" in the aircraft's model number derived from the 520 cubic inch (8.5 liter) displacement of the original Continental engine.
With the Continental TSIO-520B installation, the Bullet achieved impressive performance figures of 219 mph at sea level and 322 mph at 20,000 feet. The final Lycoming TIO-541-A configuration enabled cruise speeds of 320 mph with a remarkable climb rate of 3,000 feet per minute. In its ultimate configuration for museum display, the aircraft received a Garrett TPE331-25AA turboprop engine producing 475 horsepower, though this installation was not flight-tested.
The Manufacturer
Brokaw Aviation Inc., operated by Dr. Bergon F. Brokaw and Ernest R. Jones, focused exclusively on this single aircraft design rather than engaging in serial production. Based in Leesburg, Florida, the company's business model centered on marketing construction plans to amateur builders during the 1970s and 1980s. Unlike traditional aircraft manufacturers, Brokaw Aviation represented a personal project that evolved into a commercial venture through plan sales rather than completed aircraft production.
The company's operations effectively ceased with Dr. Brokaw's death on August 27, 2004, ending builder support for the design. No records indicate mergers, acquisitions, or name changes during the company's operational period, and it remains defunct today.
Limited Production and Construction
The BJ-520 Bullet never achieved mass production, with only one prototype and one complete plans-built example ever constructed. Gene Underland successfully completed the sole plans-built aircraft, while several other projects remained unfinished when builder support ended. This extremely limited production reflected both the aircraft's complexity and the specialized nature of its high-performance design requirements.
The prototype, registered as N520BJ with constructor number 001, incorporated the designers' initials (Brokaw and Jones) and the engine displacement in its registration. This aircraft accumulated significant flight experience but suffered substantial damage in accidents on September 14, 1985, near Eustis, Florida, and again on July 29, 1999, at Oshkosh, Wisconsin, though both incidents resulted in no fatalities.
Technical Innovation
The Bullet's design incorporated several advanced features uncommon in homebuilt aircraft of the 1970s era. The stressed aluminum structure enabled aerobatic flight operations while maintaining the strength required for high-speed performance. The retractable tricycle landing gear configuration provided improved aerodynamic efficiency compared to fixed-gear alternatives common among amateur-built designs.
With overall dimensions of 22 feet 9 inches in length, 23 feet 8 inches wingspan, and 8 feet 10 inches in height, the aircraft achieved an efficient 97 square feet of wing area. This compact design contributed to its exceptional speed performance while maintaining manageable construction complexity for amateur builders.
Legacy and Preservation
The prototype N520BJ survives today as a static display at the Sun 'n Fun Museum located at Lakeland Linder Regional Airport in Florida. Preserved with its Garrett turboprop engine installation as of 2008, the aircraft represents a significant achievement in amateur aviation design. Its status as the fastest homebuilt aircraft of its era established an important benchmark for high-performance amateur construction.
The BJ-520 Bullet's legacy extends beyond its speed records to demonstrate the potential for amateur builders to achieve professional-level performance through innovative design and meticulous construction. Despite its limited production, the aircraft proved that homebuilders could successfully create designs matching or exceeding certified aircraft performance, inspiring subsequent generations of high-performance amateur-built designs.