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Converting a Qatari-owned Boeing 747 jetliner into a new Air Force One for President Donald Trump would cost over $1 billion and take years to complete — possibly beyond the end of Trump’s current term in January 2029 — according to three aviation experts who spoke to NBC News.
Despite the jet’s current estimated value of $400 million, the process of refurbishing the 13-year-old commercial aircraft to meet presidential and military specifications would be costly, time-consuming, and riddled with technical and security challenges.
“You’re taking a 747, disassembling it, reassembling it, and then jacking it up to a very high level,” said Richard Aboulafia, managing director at AeroDynamic Advisory. “It would cost billions and take years.”
A key concern is that the aircraft would need to be completely dismantled to eliminate any potential spyware or listening devices. After that, it would need to be rebuilt with top-secret communications systems, midair refueling, missile defenses, EMP shielding, and electronic countermeasures — all of which require specialized labor and facilities.
The project could take well into the 2030s, Aboulafia warned, with the midair refueling capability alone described as “enormously time-consuming.”
Even if completed before 2029, the aircraft would reportedly be handed over to Trump’s presidential library foundation at the end of his term, requiring the removal of all classified systems, undermining much of the investment.
The White House did not immediately comment on the reported plan.
A Second Air Force One Project in Progress
The U.S. Air Force already has an active, long-delayed program to convert two Boeing 747-8s into the next generation of Air Force One aircraft. That effort, which began with a $3.9 billion fixed-price contract under the Trump administration in 2018, has ballooned to $5.3 billion and is behind schedule.
At a recent congressional hearing, Air Force officials said the aircraft might be operational by 2027, though delays continue to push that timeline. Boeing has reportedly lost money on the existing contract due to labor shortages, parts delays, and underestimated costs.
A new contract to convert the Qatari jet could offer Boeing a financial “relief”, Aboulafia said, especially if the new terms aren’t fixed-price.
“If you have to rip the plane apart, that’s more of a Boeing job,” he said. Experts noted that L3 Harris, a defense contractor with relevant experience, could also assist, particularly at their Greenville, Texas facility.
Security and Personnel Challenges
Any project to convert a plane into Air Force One must comply with intense security protocols, including employing workers with high-level “Yankee White” clearances. Boeing has previously struggled to find enough qualified workers, raising concerns that a Qatari jet conversion could face similar bottlenecks.
Additionally, the plane’s foreign ownership raises red flags. Security officials would need to painstakingly inspect every component to rule out embedded surveillance tools — a process that would significantly slow the project.
Qatari officials acknowledged discussions around the jet’s possible transfer, but stressed that no final decision has been made.
