V-22 Osprey: A Flying Shame

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Originally, the program was designed to churn out the first of more than 1,000 tilt-rotors in less than 10 years for $40 million each. But this was no conventional plane. The Osprey may cruise like an airplane, but it takes off and lands vertically like a helicopter. The technical challenge of rotating an airplane's wings and engines in midair led to delays, which in turn led to an ever higher price tag. As expenses rose, the Pentagon cut the number of planes it wanted to buy, which in turn increased the unit price. Citing rising costs, the Army abandoned the project in 1983.

That left the relatively tiny Marine Corps footing most of the bill for the project — the V-22 accounts for nearly 70% of its procurement budget — and overseeing a program larger and more technically challenging than any the service was accustomed to managing. Sensing weakness at the Pentagon, congressional supporters, largely from the V-22's key manufacturing states of Texas (Bell Helicopter) and Pennsylvania (Boeing), created the Tilt-Rotor Technology Coalition to keep the craft alive, despite Cheney's opposition. They were aided by nearly 2,000 V-22 suppliers, in more than 40 states, who pressured their lawmakers to stick with the program. And so, despite Cheney's doubts, the Osprey survived.

By 1993, as the Osprey program approached its 12th birthday and Bill Clinton became President, the Marines had spent $13 billion on the planes. None were ready for war. In 1991 one of the first V-22s crashed when taking off for its maiden flight — because of improper wiring. A second crash killed seven in 1992. The Clinton Pentagon stuck with the program through the 1990s, but in 2000 two more V-22s crashed, killing 23 Marines. With that, the Marines grounded the Osprey for 18 months.

Probes into the deadly 2000 crashes revealed that in a rush to deploy the aircraft, the Marines had dangerously cut corners in their testing program. The number of different flight configurations — varying speed, weight and other factors — flown by test pilots to ensure safe landings was reduced by half to meet deadlines. Then only two-thirds of those curtailed flight tests were conducted. That trend continues: while a 2004 plan called for 131 hours of nighttime flight tests, the Marines managed to run only 33 on the Osprey. Why the shortcuts? Problems with a gearbox kept many V-22s and pilots grounded. That meant many pilots lacked the hours required to qualify for night flying. Similarly, sea trials were curtailed because the ship designated to assist with Osprey tests could spare only 10 of the 21 days needed.