Thanks Tim. Yeah, I can come down way, way faster than anything I remotely tried with my HH, and the BDB gets warm but not overly so, it has a lot of area to spread the heat. Of course, my idea of 'fast' may be turtle slow to other folks

. All I know is that it is very fun device for me, and it has made me much more confident in my climbing.
I am curious as to why you are finding this much difference. I know that my HH will allow an almost free fall speed. It will get hot but so will my BDB if pushed the same way.
Hey, Bob! A couple of things I'd like to bring up here. First, I'm wondering if you've ever tried any bigger, fatter hitch cords, like 9 or 10mm. My gut feeling, not based on any science, is that a bigger, fatter hitch cord would provide more material to absorb and dissipate heat, and therefore maybe not get as hot as a thinner hitch cord. You do have to be sure it can grab on the rope your using, though.
Also, I had a discussion once with DSMc (Dave) about what I do to get my Hitch Hiker to tend easily. I use a knut hitch, and I tie it up as short as I possibly can by rolling the hitch cord back and down over the angled rope channel of the Hitch Hiker as I'm making up the hitch. (This seems like a shorter distance to me than the top of the Hitch Hiker.) Then when I've finished tying it, dressing and setting it, I have to work a little hard just to get the hitch to roll back up to the top of the Hitch Hiker, it's so tight.
At this point I can hardly get the rope to tend slack at all, it's so tight, which is just what I'm looking for, at this point in the process. Then I clip into my harness bridge ring, and sit back into it gently to make sure the hitch grabs and doesn't drop me.
Here is the big, important part. Once I know my hitch is holding me, and I've managed to tend a little slack, (but not at all easily; everything is still really, really tight at this point) I then sit into my harness as hard as I can, tend slack with my pulley, then do it again and again. Maybe three or four times, walking back and forth about twenty or thirty feet, tending slack each time. Frequently when I'm near the beginning of this part of the process, I find it helps to push on the spine of the Hitch Hiker to help force the hitch to stay seated at the top of the Hitch Hiker, instead of allowing it to drop back down the angled side.
By the time I'm done with this procedure, I've got a system that tends slack very easily, and a hitch with almost no sitback (or setback, I can never remember).
Having the hitch be super tight before you try to load it up is of critical importance.
This procedure might allow you to use a 10mm hitch cord and still have it grab effectively.
That's about all I wanted to say. Just looking for a way to maybe reduce heat at the hitch for you. Not sure if it will work, just giving you something to try.
Tim