Air Force One Delayed Again as Boeing Fixes Hundreds of Cracked Stringers

Boeing is facing yet another setback in its development of the next generation of Air Force One jets. The company has been working to repair hundreds of microscopic stress cracks found on two 747-8s being converted for presidential use.

The issue, which affects not only the presidential fleet but also the wider 747-8 population, is due to corrosion-induced stress. As a result, Boeing must replace approximately 300 cracked structural stringers per aircraft, adding significant time and cost to the project.

The repairs are being carried out under the direction of the Federal Aviation Administration (FAA), which has mandated their replacement. According to InsideFlyer, as of late July, 21 repairs remained on the first jet and 104 on the second.

Boeing bears all cost overruns under its fixed-price contract, limiting future flexibility and increasing financial pressure on the manufacturer. As a result, delivery of the new Air Force One jets is now expected in mid-2028, four years past the original target.