On December 14, 1986, a strange-looking aircraft — long, thin, with two fuselages, a pusher engine, a puller engine, and wings so flexible they bent visibly under their own weight — rolled down a runway at Edwards Air Force Base in California and lifted off. It was carrying so much fuel that the wingtips scraped the runway on takeoff, snapping off the winglets. Nobody turned back. Nine days, three minutes, and forty-four seconds later, it landed back at Edwards. It had circumnavigated the globe without stopping and without refuelling — the last major aviation “first” remaining to be achieved.

The aircraft was the Rutan Voyager. The pilots were Dick Rutan, a former Vietnam combat pilot with 325 combat missions, and Jeana Yeager, a pilot, record-setter, and co-designer of the project. Dick’s brother Burt Rutan had designed the aircraft. Together, over five years, they had built the machine, raised the money, trained for the flight, and argued constantly about everything — the cockpit was 7.5 feet long and 3.5 feet wide, barely big enough to change position, and one of them was flying while the other tried to sleep in it for nine straight days.

The Last Great Aviation First

By 1986, aviation records were becoming increasingly specialised. The major firsts — first flight, first transatlantic, first round-the-world, first supersonic — had all been claimed. One remained: a non-stop, non-refuelled circumnavigation. No aircraft had ever been able to carry enough fuel to go around the world without stopping or being topped up in flight.

Burt Rutan’s design solution was radical. The Voyager was built almost entirely from graphite-epoxy composite — a material that was still exotic in the mid-1980s. It was extraordinarily light: the empty aircraft weighed just 2,250 pounds. Its two engines — a Teledyne Continental IOL-200 pusher in the rear and an IOPC-200 puller in the front — were small, fuel-efficient, and derated to extend their lifespan for a nine-day flight. The aircraft carried 1,489 gallons of fuel — enough to fill the wings, the twin booms, and the centrebody to the point where fuel comprised 72% of the maximum takeoff weight. The wings, deliberately flexible to reduce stress, bent nearly five feet at the tips during the heavily loaded takeoff run.

Nine Days in a Coffin-Sized Cockpit

The Voyager’s cockpit was, by any normal standard, uninhabitable for nine days. One pilot flew while the other lay in a 5.5-foot bunk and tried to sleep through vibration, noise, turbulence, and the constant anxiety of flying a fragile aircraft over oceans at 11,000 feet. The bunk was lined with foam and a sleeping bag. There was no toilet — waste was managed with plastic bags. The food was freeze-dried. The temperature swung between cold nights over the Pacific and tropical heat over the equator.

They encountered a tropical storm over the Pacific that forced them to descend to 500 feet above the ocean at night, unable to climb high enough to fly over it and unable to go around it without running out of fuel. They flew through it. At one point, a propeller control malfunctioned and the front engine had to be restarted in flight — a procedure that had never been tested. Dick Rutan nursed the engine back to life. They continued.

The Record That Still Stands

The Voyager landed at Edwards on December 23, 1986, after covering 24,987 miles — essentially the circumference of the Earth at the equator — in 9 days, 3 minutes, and 44 seconds. They had 106 pounds of fuel remaining. The margin was tiny: had the Pacific storm been any worse, or the route any longer, they wouldn’t have made it.

The Voyager now hangs in the Smithsonian National Air and Space Museum in Washington, next to the Wright Flyer and the Spirit of St. Louis — the three aircraft that most clearly mark the boundaries of what human aviation has achieved. First flight. First Atlantic. First non-stop circumnavigation. Burt Rutan would go on to design SpaceShipOne, the first private spacecraft to reach space. But the Voyager remains his defining achievement: a machine built to do one specific thing, which did it, which will never be forgotten.

Sources: Jeana Yeager and Dick Rutan, Voyager (1987); Wikipedia, “Rutan Voyager”; Smithsonian National Air and Space Museum