In a remarkable feat of engineering and ingenuity, the U.S. Air Force has successfully combined parts from two damaged F-35A Lightning II jets, creating the world’s first fully operational “Franken-bird” fighter. The repair, which took nearly a year to complete, cost the Air Force a fraction of what a new F-35 would – just $6 million, compared to the $80 million price tag for a brand-new jet.
The two F-35s involved in the project had both suffered major damage in separate incidents. One plane had been grounded after a nose gear collapse at Hill Air Force Base in 2020, while the other was severely damaged in an engine fire at Eglin Air Force Base in Florida in 2014. Without this ambitious re-engineering effort, both jets would have likely been written off as scrap.
The rebuild was carried out by airmen from the 388th Fighter Wing at Hill Air Force Base, with support from the F-35 Joint Program Office, Ogden Air Logistics Complex, and Lockheed Martin. The team crafted custom tools and equipment to marry together the major components of the two wrecked aircraft. Once the structure was assembled, it was transported to Hill’s hangar, where the crew began the painstaking process of rewiring the aircraft, rebuilding the cockpit, and reinstalling avionics and flight systems. The radar-absorbing stealth coating was reapplied, ensuring the jet’s operational stealth capabilities.
Senior Airman Jaguar Arnold, the crew chief leading the project, described the challenge: “When we received the aircraft, it was pretty much a shell. There were a lot of tasks to complete that we hadn’t done before at the unit level.” However, after extensive ground tests and flight checks, the Franken-bird was sent to Lockheed’s Fort Worth facility for final certification.
This historic project not only demonstrates the Air Force’s resourcefulness but also provides valuable feedback for maintaining and servicing F-35s in the future. The Franken-bird will soon return to active duty with the 4th Fighter Squadron at Hill Air Force Base, marking a successful resurrection of two lost jets and a significant cost-saving achievement for the Air Force.
F35A Picture by US Air Force on Flickr CC BY-NC 2.0
