"We decided to add significant resources to support the manufacturing and testing progress of the VC-25B aircraft, and also agreed with the US Air Force on converting the certification basis from Federal Aviation Administration (FAA) standards to military standards," said Kelly Ortberg, Boeing's chairman and chief executive officer, on 28/7.

According to Ortberg, this decision will help mitigate potential risks during the certification and flight testing process, leading to an additional cost of USD 280 million in the past quarter. Boeing affirmed it would deliver the first of two VC-25B aircraft in 2028.

Bridge Aircraft VC-25B and VC-25A taking off from Joint Base Andrews, Maryland, US on 4/7. Video: USAF

Steve Parker, chief executive of Boeing's defense, space, and security division, previously mentioned the VC-25B project's budget overruns, but did not specify the exact amount.

According to Aviation Week, the VC-25B project's incurred costs reached approximately USD 2,8 billion by 2024. The newly announced amount will raise Boeing's total self-funded expenses to over USD 3 billion.

In 2018, Boeing received a fixed-price contract worth USD 3,9 billion to build two VC-25B special aircraft, based on the 747-8i passenger jet, to replace the VC-25A fleet that has been operational since 1990. The fixed-price nature of the contract requires Boeing to cover any cost overruns out of its own pocket.

The US Air Force has injected additional funds into the VC-25B program, including a USD 15,5 million contract modification in 12/2025 to support the deployment of communication systems. The US Government Accountability Office (GAO) reported that the nation's expenditure for the VC-25B project increased from nearly USD 6,3 billion to over USD 6,6 billion between 12/2018 and 8/2025.

The initial delivery date for the first VC-25B special aircraft was 12/2024, but it has been postponed multiple times. Program officials cited changes in the flight certification methodology and aircraft requirements, such as interior design, weight limits, and cargo space, as reasons for the delays.

Work to repair stress corrosion cracks on the VC-25B is currently underway and is expected to be completed this year. Many 747-8 aircraft worldwide have experienced similar issues, prompting the FAA to issue a mandatory safety directive for operators of this aircraft type in 2023.

Bridge Aircraft VC-25B at Joint Base Andrews, Maryland, US on 19/6. Photo: USAF

The delays and cost increases of the VC-25B program are closely linked to the operational Bridge Aircraft VC-25B. This aircraft is a Boeing 747-8i donated by Qatar to the US government, which is being converted into a special aircraft for the US President.

The protective capabilities of the Bridge Aircraft VC-25B gained attention earlier this month when President Trump departed the NATO summit in Turkey using an older VC-25A aircraft. He then landed at Mildenhall Air Force Base in the UK, an unscheduled stop, to switch to the Bridge Aircraft VC-25B.

The New York Times, citing informed sources, reported that before Trump left Turkey, the US Secret Service advised the US President to use the older special aircraft to ensure security amid escalating conflict with Iran.

Nguyen Tien (According to AFP, AP, Reuters, War Zone)