Boeing Fixes Flaws on Next-Gen Air Force One Jets Amid Budget Blowout

Boeing is working to repair cracked stringers on two Air Force One jets, which are being converted from Boeing 747-8s. The Federal Aviation Administration (FAA) mandated the repairs after discovering microscopic structural flaws in the aircraft's fuselage structure.

The affected components are longitudinal stringers within the fuselage of both VC-25B aircraft. According to the FAA directives, hundreds of compromised parts need to be replaced as part of the repair process.

Boeing is already facing pressure due to a $3 billion cost overrun on the project, which has exceeded its budget. The U.S. Air Force will closely monitor the repair validation before accepting the planes for operational use.

The repair work is underway at Boeing's facility, with no public delay announced yet for the presidential transport rollout. However, delays or further defects could push delivery beyond the current 2027 target.