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Skunk
Works Magic
How
a handful of men broke the rules and created the world's most amazing
high-tech weaponry.
BY
JIM WILSON
Illustrations by Mike Machat, Mark McCandlish and Lockheed Martin
Skunk Works.
Photos by Jim Wilson and Lockheed Martin Skunk Works.
The generals had botched it. Years before Pearl Harbor they had sneered
at German plans for a new type of high-speed aircraft engine. Now
in 1943, as the Allies began preparing for the D-Day invasion of France,
intelligence reports revealed that the Nazis were ramping up production
of a blistering fast fighter, a plane powered by the very same type
of propellerless "jet" engine they had rejected. The War
Department needed a miracle airplane and turned to the one man it
could count on to deliver it in six months, Clarence L. Johnson. At
age 33, "Kelly" Johnson had already established his reputation. His newest design, the twin-tailed, 400-mph P-38 Lightning, was
the most maneuverable fighterand arguably the most beautiful
airplanein the Allied force (see "Flying Battlewagons,"
May 1943, page 8). To counter the new German threat, the War Department
wanted Kelly to build a plane that could fly 200 mph faster, literally
pressing its nose against the sound barrier. The scrappy, one-time dockworker
who was often described as W.C. Fields without a sense of humor, knew
exactly what to do: He rented a circus tent.
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"Kelly"
Johnson
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Kelly
pitched his tent on the sprawling Lockheed Aircraft complex in Burbank,
Calif. Officially his shop was the Lockheed Advanced Development Projects
Unit.
The stench from a nearby plastic factory that wafted into the tent
was so vile one of the engineers began answering the phone "skonk
works," after the backwoods still in the then popular L'il Abner
comic strip. Despite these less-than-ideal working conditions, Kelly's
team of 23 design engineers and 30 shop mechanics delivered Lulu Belle,
the prototype for the P-80 Shooting Star, in only 143 days.
America had entered the jet age, more than a month ahead of schedule.
The war ended before the P-80, later designated the F-80, would
fire its first shot in anger, against Soviet MiGs in Korea. Eventually
Lockheed would build about 9000. Kelly's team moved to more permanent
quarters, in a windowless bomber-production hangar. The foul smell
that inspired the design team's name became a memory but the name
lingered.
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| Now
located in Palmdale, Calif., the Skunk Works has branched out
to include developing stealthy missiles, low-observable unmanned
aircraft like the DarkStar and reusable launch vehicles including
the X-33. Its "black projects" remain a closely guarded
secret. |
At least
until the lawyers for the L'il Abner comic strip caught wind of it.
Indeference to the comic strip, the "skonk works" was rechristened
the Skunk Works.
Whatever
the spelling, Kelly's Skunk Works is to aviation what Edison's Menlo
Park was to electricity, a place where the daily pursuit of the impossible
produces technologies indistinguishable from magic. That the Skunk
Works thrived in those early years, let alone flourished to reach
middle age, is all the more remarkable when you realize that its second
and third major projects, the Saturn cargo plane and the XFV-1 vertical-takeoff
naval fighter, were "absolute clunkers," according to Ben
Rich, Kelly's protégé and hand-picked successor. "The
open secret in the company was that Kelly walked on water in the adoring
eyes of CEO Robert Gross," Rich would later recall in his memoirs.
Building Planes
It was well-earned admiration. As a 23-year-old engineering student
at the University of Michigan, Kelly had rescued Gross's investment
in Lockheed by first spotting and then correcting a critical stability
flaw in the twin-engine Lockheed Electra. Kelly's solution, a distinctive
twin-tail, would become a Lockheed signature, appearing on the Constellation,
P-38 and the Hudson bombers Lockheed built for the British Royal Air
Force (see "Uncle Sam's War Birds On World Frontiers," Jan.
1943, page 19).
Most everyone who worked with Kelly was quick to recognize his genius.
Hall Hibbard, young Kelly's boss at Lockheed, recalled watching him
convert the Electra into the Hudson bomber during a 72-hour marathon
redesign session. "That damned Swede can actually see air,"
he later told Rich. When Kelly learned of Hibbard's remark he said
it was the greatest compliment he had ever received.
Kelly made no secret of how he worked his magic. He insisted his
engineers get dirty on the shop floor. Working a lot like guys building
hot rods in their garages, engineers and production mechanics created
the hottest planes ever to cut through the air. This informal process
produced the most important planes of the 20th century, including
the Mach 2 F-104Starfighter, U-2 and SR-71 spyplanes, and the stealthy
F-117A.
The Skunk Works' contributions to the creation of the F-22 Raptor
and Joint Strike Fighter ensure its legacy in the shape of the Air
Force of the 21st century. And its experimental stealth ship Sea Shadow
means the Skunk Works will leave its mark on future navies as well.
Building Myths
Kelly crafted the Skunk Works reputation as carefully as he engineered
his airplanes, memorializing the company's design philosophy as a
set of 14 work rules. Followed to this day, they enshrine the virtues
of speed, simplicity and cooperation while banning the evils of paperwork
and excessive management. Their
spirit, if not their precise words, has been adopted by countless
management gurus. Yet the two most important Skunk Works rules were
never committed to paper. "All of the planes were Kelly's airplanes.
And if a blue-suiter [Air Force officer] wore a star on his shoulder
only Kelly was authorized to deal with him," Rich would later
recall.
Kelly extended his "star" rule to contact with the CIA.
He insisted upon being the sole contact with the intelligence community,
which would provide the Skunk Works with its two biggest Cold War
successes, the high-flying U-2 and, later, the SR-71 spyplanes.
Resembling
the aftermath of a head-on collision between a sail-plane and an airliner,
the U-2 was the single most important intelligence tool of the Cold
War. When it was ready to fly President Dwight D. Eisenhower considered
its mission so critical to national security that he insisted on personally
approving each of its overflights of the Soviet Union. The results
were magnificent. "It really was as if we in the intelligence
community had cataracts removed," recalls former CIA director
Richard Helms. "The U-2 camera leapfrogged us into another dimension
altogether." One of the first major coups was the discovery that
a much-feared "bomber gap" between U.S. B-52 and Soviet
Bison bombers didn't exist. U-2 photos revealed that the more than
100 Bison counted flying overhead at a May Day military parade were
in fact a fleet of 30 flying in a circle.
Suntan
Russians may see SR-71 engines but not the radar-carrying stealth
blimp. Before overflights of the Soviet Union officially ended as
the result of the downing of Francis Gary Powers, the folded-optics
camera inside the U-2's "Q-bay" would capture an image that
would spur the Skunk Works to design the most impressive plane it
never built, the CL-400. The unbuilt plane would also spawn one of
its most enduring mysteries about what really takes place behind closed
hangar doors.
Intelligence work is largely a hunt for anomalies. During the height
of the Cold War no anomaly was more ominous than the release of a
scientist from the gulag, the vast network of Soviet labor camps.
When Pyotr Kapitsa, an expert on low-temperature gases arrested in
1946, suddenly found himself transferred to a Soviet research institute,
inquiring minds at the CIA wanted to know why.
Photos of hydrogen liquefaction plants taken by U-2 overflights offered
a frightening possibility: Kapitsa had been "rehabilitated"
so that he could work on the powerplant for a hydrogen-powered space
plane. During the last days of World War II, just such a plane had
been proposed as a means of bombing New York City from flights originating
in Germany. Little evidence of such a craft was ever found after the
war. The possibility that the Soviets had carried it all off lock,
stock and barrel was not beyond reason.
Terrified at the prospect of Soviet spyplanes flying over U.S. airspace
with the impunity that the U-2 crossed Mother Russia, the Skunk Works
found itself with $96 million and an assignment to build an ultrasecret
hydrogen-powered space plane to counter the new red menace.
For some time before receiving the go-ahead for Project Suntan, Kelly
had been fascinated with the idea of burning -350°F hydrogen in
a modified jet engine. In theory, such a Mach 2 craft could effortlessly
skim the atmosphere at 100,000 ft. The Skunk Works geared up to provide
the Air Force with a complete package, including a liquid hydrogen
production plant and refueling planes. Literally
overnight the Skunk Works became the world's largest producer of liquid
hydrogen, creating 200 gal. a day.
Meanwhile, the CL-400, as the Suntan hydrogen aircraft was designated,
began to take shape as a delta-wing vacuum bottle as big as a pair
of B-52s. Encouraged by initial design work, Rich recalled that Kelly
ordered 2 1/2 miles of aluminum extrusions. Pratt & Whitney was
set to work modifying engines to burn hydrogen. A guidance system
was ordered from MIT. And then Kelly spotted the critical flaw.
The CL-400 could fly. There was no question of that. What it couldn't
do was fly faster or farther than a kerosene-burning jet plane. Hydrogen
offered no technological edge. Kelly bit the bullet, and convinced
the Air Force to take back the unspent $90 million. As for the Soviet
plane, it never materialized. It seems hydrogen-fuel expert Kapitsa
had been freed to work on another project that had somehow escaped
the CIA's notice, the launch of Sputnik, the world's first successfully
orbited artificial satellite. In 1978, he would win the Nobel Prize.
Aurora
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Jack
Gordon
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The CL-400 vanished from the Skunk Works but the mythology surrounding
a liquid hydrogen spyplane remained and in time would grow to become
one of the great Skunk Works mysteries, Aurora.
The Air
Force and Lockheed insist Aurora is a code name for the company's
work on its entry in the B-2 stealth bomber design competition, which
was won by Northrop Aircraft.
Those who chase mystery aircraft point to two facts that suggest
there may be more to the story. There have, they claim, been repeated
sightings of a mystery craft of the CL-400-like proportions moving
at high speed. There is also documentation of a NASA-financed project
that overcame the technical roadblocks that caused Suntan to stumble.
In the early 1970s Gerald Rosen, a professor of physics at Philadelphia's
Drexel University and one of the highest paid theoretical physicists
in the United States, was contracted by NASA to determine whether
it would be possible to store hydrogen as individual atoms rather
than as molecules. His calculations predicted it was not only possible,
but that so much fuel could be stored in a small space that the Apollo
astronauts could have traveled to the moon in a rocket the size of
a pickup truck. And so, official denials ignored, Aurora remains a
lively topic for speculation.
The Fastest Plane
Despite the termination of Suntan, the Skunk Works got to build a
fast, high-flying spyplane, the SR-71 Blackbird. Designed for Mach
3 plus flight (see "The Blackbird Is Back," June 1991, page
27), the SR-71 holds a slew of records that are not likely to be broken
for decades to come. Like the U-2, the SR-71 also began as a CIA project.
And like the U-2, its role was obsoleted by technology, in this case
American technology in the form of CIA and National Reconnaissance
Office spy satellites. Today, most SR-71s, and their predecessor A-12s,
are featured attractions at air museums. NASA continues to operate
one SR-71 for environmental research. A second, operated by the Air
Force, is used from time to time in technology demonstration experiments,
according to military sources.
It was a far different fate than Kelly had envisioned for the SR-71.
Much as he had adapted the Electra to become the British Hudson bomber,
Kelly envisioned manufacturing fleets of the SR-71 specially modified
as bombers, fighters and missile launchers. The government rejected
the idea and, in a decision that will live in infamy for aviation
enthusiasts for centuries to come, ordered the Skunk Works to destroy
all SR-71 tooling.
Before being killed in its prime, the SR-71 took part in an experiment
that would pave the Skunk Works' entry into the next frontier of high-altitude
surveillance, Tagboard. The project tested the feasibility of using
the SR-71 to launch a high-speed, high-altitude drone, the D-21, deep
into enemy terrain. After a series of tries, including one that ended
in the loss of a plane and its pilot, Tagboard was canceled.
Combining the lessons learned from Tagboard with the stealth technology
it would later develop for Have Blue, the prototype for the F-117A
(see "Black Jet," July 1990, page 43), the Skunk Works would
work with Boeing to develop DarkStar. Using
this low-observable, high-altitude, long-endurance unmanned aircraft,
the Air Force will be able to undertake reconnaissance missions too
far into hostile terrain for manned aircraft and too expensive for
satellites.
Future Planes
Changing times have rendered the legendary planes of the Skunk Works
militarily obsolete. Kelly and Rich have passed on. In May 1995, following
the merger of Lockheed and Martin Marietta, the new Lockheed Martin
company spun off the Skunk Works as a separate Lockheed operation,
based in Palmdale, Calif. Today, a new generation of designers, plane
builders and test pilots under the leadership of president Jack Gordon
carries on the best of the old Skunk Works traditions. A prototype
for Venture Star, a possible replacement for NASA's space shuttle,
the X-33 itself is being considered as a testbed for a future military
space plane. Tales of mystery craft continue. There have been scores
of sightings of a 1000-ft.-long stealth blimp that supposedly carries
a massive phased array radar. The craft is said to disguise itself
by using "optical stealth" technology that creates an image
of a floating star field.
By their nature, the type of "black projects" undertaken
by the Skunk Works always have and always will be secret. What PM
has learned through its conversations with company executives and
test pilots and visits to nonrestricted parts of the Skunk Works is
only as much as the company and government are willing to share. It
is certain that there is far more to the Skunk Works story than can
now be told. Looking at the tall white hangars gleaming in the high
desert sun, we can't help but wonder what 21st century wonders are
taking shape inside.

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