Boeing takes another $280M loss on Air Force One, total overruns exceed $3 billion

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Boeing has taken a fresh $280 million loss on work to deliver two newly converted and fully equipped VC-25B Air Force One presidential aircraft to the U.S. Air Force. The company says the new cost growth reflects investments to help it keep on track to finally deliver the first of these planes in 2028. The program remains years behind schedule, as well as over budget, with Boeing now having paid more than $3 billion out of pocket. This all also follows last week’s announcement that the Qatari-gifted VC-25B Bridge jet will be pulled from service for roughly a month to receive additional upgrades amid concerns that it lacks adequate defensive and other capabilities.

The new loss, or “charge,” on the VC-25B effort was announced during a quarterly Boeing earnings call this morning. Steve Parker, President and CEO of Boeing’s Defense, Space, and Security division, had first disclosed new cost growth on the program in an interview with Aviation Week earlier this month, but did not provide a specific dollar figure at that time. The Air Force has been actively working to acquire the two VC-25Bs as one-for-one replacements for its aging VC-25A Air Force One aircraft since the late 2010s.

One of the Air Force’s existing VC-25A Air Force One jets. USAF

Boeing is doing the VC-25B conversion work under a firm, fixed-price contract, and has already absorbed billions of dollars in losses since the program began. As of 2024, Boeing had reported some $2.8 billion in charges, according to Aviation Week . The new $280 million charge would push that figure to over $3 billion.

The Air Force has infused some additional funding into the effort, as well. This includes a $15.5 million contract modification to support communications systems work in December 2025. In a report published in June , the Government Accountability Office (GAO) said the total estimated acquisition cost of the program on the U.S. government side had risen from $6.263 billion to $6.608 billion between December 2018 and August 2025.

“We’ve made the decision to add significant resources to support the build and test schedule on VC-25B. We have also aligned with the Air Force on moving from an FAA [Federal Aviation Administration] to a military certification basis,” Boeing President and CEO Kelly Ortberg said during today’s earnings call. “These additional resources will also help mitigate potential risks during certification and flight tests. Since this program is in a reach-forward loss, these additional investments resulted in a $280 million charge during the quarter.”

“Results include $280 million of losses on the VC-25B program primarily driven by an investment in additional production and certification resources,” Boeing added in a press release put out today. “The company continues to anticipate first delivery in 2028.”

Boeing first announced last year that it was aiming to deliver the first fully-equipped VC-25B by mid-2028. GAO’s report in June said the Air Force hopes to receive the aircraft by March of that year. If Boeing holds to this timeline, it will represent a slight improvement in the program schedule. However, the original goal was for the Air Force to have the first of these new Air Force One jets in hand by December 2024.

Another look at one of the older VC-25A Air Force Ones. USAF

“In September 2025, Boeing provided a revised schedule that would accelerate the aircraft delivery, to mid-2028 and mid-2029, respectively. Program officials said the revised schedule reflects changes to the airworthiness certification approach and aircraft requirements, including interior designs, weight limitations, and storage,” per GAO’s report in June. “They said that the supply chain is ramping up to ensure that parts are delivered on time to support the schedule. They also noted that they are exploring use of the organic industrial base to mitigate supply chain risks and ensure a diversity of suppliers.”

“Repairs of the VC-25B stress corrosion cracks are ongoing and are expected to be completed in 2026, according to officials. They are planning ongoing inspections after delivery,” the report added. “The Air Force plans to upgrade mission communications systems after the aircraft are delivered, but the timelines are still being developed, according to program officials.”

Cracking is a known issue that has been impacting 747-8s worldwide, regardless of their configuration. The FAA issued a formal airworthiness directive to all operators regarding these problems back in 2023.

The additional work required on the communications systems also speaks to the fact that delays on such a complex program inherently mean that certain technologies intended to be incorporated originally have become out of date.

“The program is developing 80 certification plans to demonstrate aircraft airworthiness,” GAO also noted. “The Air Force approved seven of these plans as of October 2025. The Air Force has yet to determine when operational testing will begin.”

Delays and cost growth in the conversion of the two fully fledged VC-25Bs are deeply intertwined with what is now known as the VC-25B Bridge aircraft. Issues related to Air Force One had already been of personal interest to President Donald Trump since he was just a candidate back in 2015. Reports that he was looking for ways to speed up the acquisition of a new Air Force One plane emerged soon after he started his second term last year. The Qatari government subsequently made the highly irregular donation of the 747-8i jet to the U.S. military, after which the Air Force announced it would be turned into an interim presidential aircraft. Defense contractor L3Harris did the conversion work in a span of roughly 10 months .

The VC-25B bridge aircraft seen at its official rollout. USAF

The basic justification for needing the Bridge VC-25B at all remains a subject of intense debate, and the aircraft has been a source of criticism and controversy from the start. This has been further fueled by a recent chain of events that began with the Bridge jet’s official entry in service in the Air Force One role earlier this month.

Trump took his first trip on the plane on July 1, traveling to Montana for events surrounding the 250th anniversary of the United States. Just days later, the President traveled to the NATO summit in Turkey on the aircraft, but then made an unexpected swap back to an older VC-25A on the return flight home. It has since been reported that a credible threat to Trump emanating from Iran prompted the Secret Service to advise the switch in aircraft. There were reports before and after saying the ex-Qatari 747 lacked key self-defense features and other capabilities that are found on the VC-25As and that will be included on the future VC-25Bs from Boeing.

POTUS has just departed Turkey on the “Old Air Force” (VC-25A) Speculating if it will meet the new VC-25B Bridge in the UK for a fuel stopover and POTUS will return to Andrews on the VC-25B Bridge. pic.twitter.com/Xm4qOt52uq

— Thenewarea51 (@thenewarea51) July 8, 2026

Trump departs Türkiye following the conclusion of the NATO Summit. pic.twitter.com/iWhBCb31dI

— Clash Report (@clashreport) July 8, 2026

TWZ had repeatedly raised serious questions about potential defense capabilities, as well as the overall feasibility of using the former Qatari plane in the Air Force One role, since the plan first emerged. Before the Turkey trip, whether the Bridge jet would ever fly overseas in the Air Force One role was an open question.

The VC-25As do certainly have defensive and other capabilities that are not so plainly visible, and the VC-25Bs could, as well. The White House, the Air Force , and L3Harris have consistently pushed back on any operational security concerns.

At the same time, President Trump announced last week that the Bridge aircraft will be sent off to have its capabilities “maxed out.” The White House subsequently confirmed this and that the jet is expected to be out of service for roughly a month. This has raised a host of new questions about the aircraft’s configuration and what risks may have been accepted to meet the original delivery schedule, as TWZ has previously laid out in detail .

Say less. pic.twitter.com/H21A9krXuS

— The White House (@WhiteHouse) July 20, 2026

It is worth noting here that there have also been signs that the requirements for the fully-equipped VC-25Bs have been watered down over the years , at least to a degree, to try to accelerate that program. This includes the notable lack of an in-flight refueling capability on the jets that Boeing is converting now. The VC-25As have the ability to refuel in flight, and the Air Force has described this as a key capability in the past, as you can read more about here .

In the meantime, the VC-25As look set to continue to serve at least through 2028. It is also worth noting that one of the service’s Boeing 757-based C-32A aircraft took President Trump on a trip to Michigan on Monday. The use of the C-32As in the Air Force One role is not at all uncommon, especially on domestic trips to smaller airports. However, use of the C-32s for presidential travel has increased as VC-25A availability has waned due to the age of those aircraft.

Today, one of our Heartlander reporters @maggiewlittle is traveling aboard Air Force One as part of the White House press pool, covering President Trump's visit to Michigan. Follow along for updates throughout the day. pic.twitter.com/Ub1V40qbl7

— Heartlander News (@HeartlanderNews) July 27, 2026

Despite the financial loss announced today, Boeing is still pressing ahead to finally deliver the first fully-equipped VC-25B, now hopefully set to come in 2028. What will happen to the Bridge aircraft afterward, and how it will continue to be utilized between now and then, remains to be seen.

Contact the author: joe@twz.com

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