Boeing Aims for 2027 Air Force One Delivery Amid $2 Billion Cost Overruns and Requirement Changes

Boeing may deliver the next-generation Air Force One by 2027, two years earlier than previously projected, if the U.S. Air Force relaxes certain requirements. This was discussed during a congressional hearing, highlighting the VC-25B program's issues with delays and cost overruns. The $3.9 billion contract is now $2 billion over budget. The revised timeline could allow President Trump to use the aircraft before his term ends in January 2029. The Air Force and Boeing are negotiating requirement changes to expedite delivery, including easing security clearance mandates for Boeing personnel.

A Program Years Behind Schedule

The VC-25B program, which involves converting two Boeing 747-8 aircraft into highly customized presidential transports, was originally scheduled for delivery in 2024. However, a series of delays pushed the expected handover to as late as 2029. The aircraft, initially built for the now-defunct Russian airline Transaero, have been undergoing conversion at Lackland Air Force Base in San Antonio since 2019. Despite being nearly a decade old, the planes have logged fewer than 20 flight hours and are considered virtually new.

The Air Force and Boeing are now working to accelerate the timeline by streamlining requirements. Darlene Costello, the acting assistant secretary of the Air Force for acquisition, told lawmakers during a House Armed Services Committee hearing on May 7 that Boeing has proposed a 2027 delivery date—contingent on the relaxation of certain specifications.

“We are looking at the requirements that are being potentially traded off to get to that date,” Costello said. “I would not necessarily guarantee that date, but they’re proposing to bring it into ’27.”

Cost Overruns and Contractual Strain

The VC-25B program has become a financial burden for Boeing. The company has acknowledged that the project is now $2 billion over budget, a significant overrun on the $3.9 billion fixed-price contract signed in 2017. The fixed-price nature of the deal means Boeing must absorb the excess costs, which has added pressure to deliver the aircraft as soon as possible.

The Air Force has confirmed that the program has exceeded the “significant” cost-growth threshold under the Nunn-McCurdy Act, though it has not yet triggered a “critical” breach that would require a full program review and potential restructuring.

“We don’t believe it’s going to be a critical Nunn-McCurdy,” Costello said. “But we are beyond the significant threshold and we’re working through the process to inform Congress of that.”

Requirement Changes to Expedite Delivery

To meet the 2027 target, the Air Force and Boeing have already agreed to relax some program requirements. One notable change is the removal of a mandate that all Boeing personnel working on the aircraft hold top-level security clearances—a stipulation that had previously contributed to staffing delays.

Other potential requirement changes are still under discussion. Costello emphasized that while some capabilities may be adjusted, the aircraft will still meet the core mission of secure presidential transport.

“We are absolutely committed to delivering an aircraft with the communications and defensive capabilities required for presidential transport,” she said.

The Air Force is also coordinating with the White House to determine which capabilities are essential and which can be deferred or eliminated to speed up production.

Political Pressure and Interim Solutions

The delays have drawn sharp criticism from President Trump, who has reportedly explored interim solutions to bridge the gap until the VC-25Bs are ready. According to multiple reports, the administration has tapped defense contractor L3Harris to retrofit a Boeing 747 previously owned by the Qatari royal family for temporary presidential use. That aircraft could be ready as early as fall 2025.

Boeing CEO Kelly Ortberg acknowledged the president’s frustration and said the company is working with Department of Government Efficiency chief Elon Musk to eliminate “non-value added constraints” that have slowed progress.

Aircraft Background and Technical Details

The two aircraft designated to become the VC-25Bs—registration numbers N894BA and N895BA—first flew in 2016 and are powered by four GEnx-2B67 engines. Despite their age, the planes are considered low-time airframes due to their minimal flight history. Their conversion into presidential aircraft involves extensive modifications, including advanced communications systems, defensive countermeasures, and in-flight refueling capabilities.

The Air Force One designation is reserved for any Air Force aircraft carrying the president, but the VC-25B will serve as the primary long-range transport for the commander-in-chief, replacing the aging VC-25A fleet based on the Boeing 747-200 platform.

A Tentative Path Forward

While the 2027 delivery date is not guaranteed, it represents a significant improvement over previous estimates. As recently as February 2025, Boeing had projected delivery as late as 2029. The new timeline, if achieved, would allow President Trump to use the aircraft during his current term, which ends in January 2029.

However, the path to 2027 hinges on continued cooperation between Boeing, the Air Force, and the White House. The final delivery schedule will depend on which requirements are ultimately retained or modified.

“We’re working with the White House on what’s acceptable from a capability standpoint for those aircraft, and we will refine the date accordingly,” Costello said.

Boeing Aims for 2027 Air Force One Delivery Amid $2 Billion Cost Overruns and Requirement Changes

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