US Air Force builds $80M F-35A for just $6M by merging parts from two crashed jets
In a notable achievement, Airmen from the 388th Fighter Wing have successfully restored an F-35A Lightning II aircraft, merging the remnants of two damaged jets into a single operational unit.
This marks the first instance of maintainers creating an airworthy F-35A by combining components from separate aircraft.
The restoration project stemmed from the need to salvage an aircraft damaged in a nose gear collapse in 2020 at Hill Air Force Base, while the other had suffered an engine fire at Eglin Air Force Base in Florida in 2014.
The endeavor has been locally dubbed the 'Franken-bird' due to its unique origins.
This interagency initiative involved collaboration among key entities, including the F-35 Joint Program Office, the Ogden Air Logistics Complex, the 388th Fighter Wing, and Lockheed Martin.
Throughout the restoration process, teams at Hill developed specialized tools, stands, and equipment to aid in merging various aircraft sections, with much of the initial work accomplished at the Ogden Air Logistics Complex.
The aircraft was returned to the 388th Fighter Wing in November 2023.
Scott Taylor, Lockheed Martin's lead mechanical engineer for the project, noted that the methods and resources implemented during this phase could be valuable for aircraft repairs in combat settings.
For the past year, the restored aircraft has been housed within the 4th Fighter Generation Squadron, where maintainers have been focused on completing its restoration.
Senior Airman Jaguar Arnold, serving as the crew chief for the aircraft, acknowledged the extensive challenges faced during the rebuilding process.
'When we received the aircraft, it was essentially just a shell,' Arnold stated, highlighting the wide range of tasks they were required to tackle, many of which were new to their unit.
The restoration involved critical tasks such as re-installing landing gear with attention to the aircraft's center of gravity and procuring and implementing various components, including 'belly bands' and flight controls.
The Airmen collaborated closely with engineers and technicians from Lockheed Martin to rewire the systems, rebuild the cockpit, overhaul avionics, and install components typically uncommon in routine maintenance environments.
Additionally, the team was responsible for fabricating and applying coatings to restore the aircraft's low-observable features.
1st Lt. Ryan Bare, Sortie Generation Flight commander for the 4th FGS, noted the team's dedication. "We put in long hours, often working nights and weekends," Bare remarked.
Balancing the demands of this ambitious restoration with the regular maintenance needs of an active fighter squadron posed logistical challenges for squadron leadership.
However, the team successfully navigated these obstacles, reaping rewards from the experience gained.
Bare added, 'Taking on this project at the field level was unprecedented and came with its difficulties, but it also made for an invaluable opportunity for our maintainers to enhance their skills.'
The lessons learned from this unique project are expected to influence updates to the Joint Technical Data used by F-35 maintainers, promising improved safety for aircraft, maintainers, and pilots.
Financially, the Air Force stands to benefit significantly from this endeavor.
The project's estimated cost was nearly $6 million, starkly contrasting to the expense of a new F-35A, which exceeds $80 million.
Upon successful functional check flight, the aircraft will undergo final certification at Lockheed Martin's Fort Worth, Texas.
Afterward, it is set to return to Hill Air Force Base, where it will rejoin the 4th Fighter Squadron fleet.
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