While filming a documentary in Wyoming, US in 2005, Mears was involved in a serious accident. The helicopter in which he and his camera crew were travelling hit the ground during a steep low level turn, and broke apart, rolling to a stop. The fuel tank was ruptured in the accident and escaping fuel covered Mears and the crew. No fire occurred, and Mears was able to escape the wreckage uninjured and assist in the rescue and administer first aid to one of the crew who was badly hurt.