On June 10, 1990, what was supposed to be a routine flight from Birmingham, UK, to Malaga, Spain turned into one of the most terrifying and miraculous survival stories in aviation history. British Airways Flight 5390, a BAC One-Eleven aircraft, had just taken off with 81 passengers and six crew members when, 13 minutes after takeoff, disaster struck at 17,300 feet over Oxfordshire.
The aircraft’s left cockpit windscreen suddenly blew out, causing an explosive decompression that nearly cost the life of Captain Timothy Lancaster. In an instant, he was sucked out of the cockpit, leaving only his legs inside the aircraft.
This incredible survival story, full of heroism, quick thinking, and sheer luck, would later become one of the most studied aviation incidents in history.
The Moment of Disaster: A Cockpit Nightmare
The decompression force was so intense that it blew open the cockpit door, sending a violent rush of wind and debris through the cabin. Paperwork, loose items, and a powerful gust of air filled the flight deck. Flight attendant Nigel Ogden, who was entering the cockpit at that moment, witnessed the horrifying sight of Captain Lancaster being pulled out of the aircraft.
Thinking fast, Ogden lunged forward and grabbed Lancaster’s legs before he could be fully ejected. The captain was now halfway outside the plane, exposed to hurricane-force winds, extreme cold, and the sheer terror of being dragged through the sky at over 300 mph.
Despite the -17°C (1.4°F) temperature, the intense wind, and the aircraft’s vibrations, Ogden held on for dear life.
Meanwhile, Co-pilot Alastair Atchison, suddenly left in command, took control of the aircraft. With the plane losing pressure rapidly and alarms blaring, he knew he had to act fast.
Keeping the Captain Alive: A Battle Against the Elements
With Captain Lancaster still hanging outside the aircraft, his head and upper torso dangerously close to the plane’s left engine intake, it seemed impossible that he would survive. His eyes were wide open but unresponsive, and the crew feared he was already dead.
Adding to the chaos, the severe turbulence and cold made it difficult to communicate or move around the cockpit. The crew’s oxygen masks had deployed, further limiting their ability to coordinate.
Realizing he needed help, flight attendant John Heward rushed into the cockpit to assist Ogden. Together, they fought against the wind, trying to pull Lancaster back inside. But the decompression was so strong that his body was pinned against the aircraft’s exterior, and bringing him back in was impossible.
Instead, they managed to secure his legs against the cockpit seat, preventing him from being fully sucked out.
Co-Pilot Atchison’s Heroic Piloting
While the cabin crew struggled to hold onto Lancaster, Atchison made a split-second decision to initiate an emergency descent. He knew that lowering the altitude was the only way to restore normal cabin pressure and increase oxygen levels.
He quickly radioed air traffic control and declared a Mayday emergency, requesting an immediate diversion to Southampton Airport. However, communication was incredibly difficult due to the deafening wind noise and cockpit chaos.
Despite these obstacles, Atchison remained calm. He carefully navigated the aircraft down to 11,000 feet to stabilize pressure, ensuring passengers and crew could breathe more easily.
The Struggle Continues: 20 Minutes of Sheer Terror
For an agonizing 20 minutes, the crew held onto Lancaster, who remained motionless and covered in ice.
- His body was battered by the relentless 300 mph wind.
- His arms flailed uncontrollably, his face was frozen, and he showed no signs of consciousness.
- The crew feared he was dead but refused to let go.
Ogden, who had been holding onto Lancaster since the decompression, began losing his grip due to frostbite and exhaustion. Eventually, another flight attendant, Simon Rogers, stepped in to take over.
At the same time, Atchison focused entirely on landing the aircraft, a task made extremely difficult due to the wind resistance and the partially open cockpit.
The Miracle Landing
Despite the extreme conditions, Atchison expertly brought the aircraft down to Southampton Airport, touching down at 07:55 a.m. Emergency crews were already on standby, expecting to recover a deceased captain.
But when the aircraft came to a stop and rescuers rushed into the cockpit, they discovered something truly astonishing—Captain Lancaster was alive!
The Aftermath: A Stunning Survival
Miraculously, Lancaster had survived the entire ordeal with only minor injuries.
- He suffered frostbite, bruises, cuts, and a few broken bones.
- His biggest injury was shock and severe exposure to the cold.
- Despite being unconscious for most of the event, he regained full awareness after landing.
Amazingly, he returned to flying just five months later, proving his resilience and determination.
As for Atchison, his incredible handling of the aircraft earned him immense praise. He later received the Queen’s Commendation for Valuable Service in the Air.
The flight attendants, especially Nigel Ogden, John Heward, and Simon Rogers, were also honored for their bravery in holding onto Lancaster for over 20 minutes in near-impossible conditions.
The Investigation: A Small Mistake with Huge Consequences
The UK Air Accidents Investigation Branch (AAIB) conducted a thorough investigation into the incident. What they found was shocking:
- The cockpit windscreen had been replaced just 27 hours before the flight.
- The maintenance technician had used the wrong bolts—too small by just 0.66 mm.
- The incorrect bolts could not withstand the cabin pressure, leading to the failure.
This tiny 0.66 mm mistake nearly caused an aviation disaster.
As a result, British Airways and other airlines immediately revised their maintenance protocols, ensuring stricter quality checks for all cockpit windscreen replacements.
Lessons from Flight 5390: The Importance of Training and Quick Thinking
This incident remains one of the most astonishing survival stories in aviation history. It highlights:
The importance of rigorous aircraft maintenance and safety checks.
The heroic composure of flight crews under extreme pressure.
The importance of pilot training in crisis management.
Had it not been for:
- Atchison’s expert piloting
- The crew’s determination to hold onto Lancaster
- Quick coordination with air traffic control
…the outcome could have been tragically different.
Final Thoughts
The story of British Airways Flight 5390 is not just a tale of survival—it is a lesson in human resilience, teamwork, and the absolute necessity of precision in aviation maintenance.
Though it was a terrifying ordeal, it led to improved safety standards that continue to protect passengers worldwide.
Captain Timothy Lancaster’s miracle survival remains one of the most incredible real-life aviation stories ever recorded—a story of a man who defied death at 17,000 feet and lived to tell the tale.
