Converting a Qatari-owned 747 jet into a new Air Force One for President Donald Trump is projected to involve the installation of multiple top-secret systems, with costs exceeding $1 billion and a timeline that may stretch over several years, as reported by three aviation experts to NBC News. They highlighted that accepting the 13-year-old jet could end up costing U.S. taxpayers hundreds of millions of dollars in the long run, especially since refurbishing the commercial aircraft would surpass its current valuation of $400 million.
The process of transforming the Qatari jetliner into Air Force One might not be completed by the end of Trump’s term in 2029. At that point, the aircraft is expected to be handed over to Trump’s presidential library foundation. Richard Aboulafia, an analyst and consultant specializing in commercial and military aviation, indicated that the overall cost could reach billions and take years to finalize. “You’re taking a 747, disassembling it, reassembling it, and then jacking it up to a very high level,” said Aboulafia, who serves as the managing director at AeroDynamic Advisory, a well-respected consulting firm.
The White House has yet to respond to inquiries regarding this potential aircraft transformation, but aviation experts assert that Air Force One is regarded as the most complex aircraft globally. Its role extends beyond mere transportation; it serves as a secure communication center in the sky, facilitating command and control of nuclear weapons and allowing the president to issue critical orders during emergencies or wartime.
Experts believe that the proposal to convert the Qatari 747 into Air Force One lacks both financial and practical viability. Boeing is already engaged in a multiyear project to convert two 747s to replace the current Air Force One planes. It is anticipated that the refurbishment contract for the Qatari 747 would most likely be awarded to Boeing, given its status as the original manufacturer. “Since you’re also disassembling and reassembling the jet for security reasons, you’re probably going to go with the people who know it better,” Aboulafia explained. “If you have to rip the plane apart, that’s more of a Boeing job.”
Some aspects of the refurbishment could potentially be managed by L3 Harris, a company that specializes in such intricate modifications. The majority of the work is expected to occur in Greenville, Texas.
The Qatari jumbo jet would need to be meticulously dismantled to eliminate any potential listening devices, spyware, or security vulnerabilities that could allow foreign entities to eavesdrop on the president’s aircraft. Following this, it would require the installation of advanced systems for secure government communications, midair refueling capabilities, missile defense, countering electronic jamming, and protection against electromagnetic pulse attacks. Moreover, accommodations for White House medical staff and the Secret Service would likely need to be included in the design.
According to Aboulafia, the installation of these new systems may extend the project timeline into the 2030s. He noted that equipping the aircraft with midair refueling capability alone would be “enormously time-consuming.” The White House has indicated that the jet is expected to be transferred to Trump’s presidential library foundation by the conclusion of his term in January 2029, which would necessitate the removal of all sensitive government equipment from the aircraft.
While Trump could theoretically override existing Air Force security protocols, typically, personnel working on presidential aircraft or similarly sensitive projects require a high-level security clearance known as a “Yankee White” clearance. An industry insider, who preferred to remain anonymous, revealed that Boeing has historically faced difficulties in sourcing enough workers with the necessary security clearances to conduct the required work.
In 2018, the Air Force awarded Boeing a contract to convert two 747s into new Air Force One aircraft for a budget of $3.9 billion. However, in 2019, the Pentagon revised the estimated total cost of building, equipping, and testing these planes to approximately $5.3 billion. The project has encountered several delays and cost overruns, with the jets originally scheduled for delivery last year now expected to be completed by 2029.
During a congressional hearing on May 8, Darlene Costello, principal deputy assistant secretary of the Air Force for acquisition, technology, and logistics, informed lawmakers that the new planes could potentially be ready by 2027 if some requirements were relaxed. In a statement made in 2022, Boeing’s then-CEO, Dave Calhoun, suggested that the company should not have agreed to the Trump administration’s terms for the new Air Force One in 2018. For Boeing, converting the Qatari jetliner under a new contract could provide a much-needed financial reprieve, as the company has incurred significant losses from the fixed-cost contract it accepted during Trump’s first term, primarily due to absorbing major cost overruns. Aboulafia remarked, “This would be a real relief for Boeing.”
