The F-35 Joint Program Office (JPO), in collaboration with Lockheed Martin and the 388th Fighter Wing Maintenance Group, completed the first-ever transplant of a forward fuselage section between two damaged F-35A jets. The initiative began in late 2022 and concluded after more than two years of meticulous work.
The two aircraft involved—AF-27 and AF-211—had been out of service due to separate incidents in 2014 and 2020. Rather than write off both aircraft, engineers removed the nose from AF-27 and fitted it onto AF-211, creating a fully functional jet while significantly reducing costs.
“The scope and complexity of this project was an exemplary demonstration of overcoming barriers and achieving a greater tier of major aircraft repair capability for an advanced tactical fighter,” said Tomas Barber, an engineer with the F-35 JPO Major Mishap Repair Team. The repair process lasted two years and five months, with a total cost of $11.7 million—$2.8 million under budget.
This innovative approach avoided the need to purchase a new aircraft, saving approximately $63 million for the F-35 programme and, ultimately, the US Department of Defense and taxpayers. The JPO highlighted the project as a clear example of its commitment to continuous improvement and resource efficiency.
The rebuilt jet, now redesignated as AF-17, completed its first post-repair flight on 24 January 2025, flying from Hill Air Force Base in Utah to Lockheed Martin’s facility in Fort Worth, Texas. “A testament to the process developed here is that the rebuilt aircraft’s first flight was flown to the edges of the performance envelope, and it performed like it was fresh from the initial production line,” said Jeffrey Jensen, the F-35A variant lead.
Now assigned to the 4th Fighter Generation Squadron of the 388th Fighter Wing, AF-17 is fully operational and integrated back into the fleet. The success of this repair marks a milestone in military aviation and showcases the F-35 programme’s adaptability and cost-conscious innovation.
