A one-of-a-kind F-35 stealth fighter built from two wrecked aircraft is set to make an unprecedented return to the US Air Force’s operational fleet.
The so-called “Franken-bird” was restored through a collaboration between airmen from the 388th Fighter Wing at Hill Air Force Base in Utah, the F-35A Lightning II Joint Program Office, and Lockheed Martin.
The F-35 JPO first assessed the feasibility of the restoration project in January 2020, and work on a pieced-together stealth fighter began in late 2023 at the Ogden Air Logistics Complex.
“All of the aircraft sections can be de-mated and re-mated theoretically, but it’s just never been done before,” Scott Taylor, Lockheed Martin’s lead mechanical engineer on the project, said in a press release announcing the project in 2023. “This is the first F-35 ‘Frankin-bird’ to date. This is history.”
Less than two years later, the “Franken-bird” jet made its maiden flight on January 16. Following the successful functional check flight, the salvaged F-35 is set to undergo final tests and work before returning to combat status.
Scrap to salvage
In 2014, an F-35, tail number AF-27, was severely damaged at the Eglin Air Force Base in Florida after an engine fire burned the rear two-thirds of the aircraft. The cost of damage was estimated to be over $50 million, according to the Air Education and Training Command. The airframe was recycled as a damage and repair trainer for maintenance crews
In 2020, a landing gear malfunction caused an F-35, tail number AF-211, to crash, severely damaging its nose. The damaged airframe and its engine were preserved at Hill Air Force Base in Utah since the landing gear collapse.
Dave Myers, the lead engineer at the F-35 Joint Program Office Lightning Support Team, told Air & Space Forces Magazine that there was “no degradation” to the airframes, so splicing them together into the “Franken-bird” wouldn’t impact its capabilities.
The first ‘Franken-bird’
Hangared in the 4th Fighter Generation Squadron, maintainers created unique tools and equipment to support and join the nose section of the AF-27 and the rear section of the AF-211 since it was the first attempt at the ambitious repair job.
“When we received the aircraft, it was pretty much a shell,” Senior Airman Jaguar Arnold, the aircraft’s crew chief from the 4th FGS, said in a statement released last month. “There were a lot of tasks to complete that we hadn’t done before at the unit level.”
The repair process also incorporated some technical updates and new components, including reinforcement structures on its outer shell. Technicians reinstalled the landing gear, rewired the avionics systems, and rebuilt the cockpit.
“The F-35 program is still young compared to all legacy airframes,” Myers said. “We are doing this for the first time, and organizationally for the future, we are creating a process we can move forward with.”
A $6 million refurbished aircraft
The resounding success of the F-35 restoration efforts provided valuable technical experience for maintainers to improve installation and inspection processes.
“When we took responsibility for this project, we were taking on something unprecedented at the field level, and it wasn’t easy,” 1st Lt. Ryan Bare, Sortie Generation Flight commander for the 4th FGS, said. “That can’t be overstated.”
“But we were also taking on an opportunity for our maintainers to gain proficiency in this type of work and build experience at the unit level,” Bare added. “As a program, and as a unit, we’ve benefited greatly from this.”
The “Franken-bird” also had the added benefit of growing the Air Force’s operational fleet — at a fraction of the cost. The aircraft restoration project cost an estimated $6 million, whereas a new F-35 jet costs over $80 million.
While the F-35 is the Defense Department’s most advanced and costliest weapon system, Congress has questioned whether the stealth fighter’s capabilities justify its steep price tag, especially as the program continues to be plagued by cost overruns, production delays, and maintenance and performance issues.
The DoD extended the F-35’s projected operational life from 2077 to 2088, prompting the total estimated cost of the program to exceed $2 trillion. The US military operates about 630 F-35 variants with plans to procure over 1,800 more jets for the Air Force, Marine Corps, and Navy by the mid-2040s.
Return to the fleet
After the “Franken-bird” completed its functional check flights in January, the aircraft was transported to a Lockheed Martin facility in Fort Worth, Texas, where it will complete final certifications to restore its combat-ready status.
The section behind the jet’s nose, which is only covered with anti-corrosion primer, will also be finished by applying low-observable materials.
The aircraft is set to return to combat status with the 4th Fighter Squadron around March, though it could be fully operational well before then, according to Dan Santos, the F-35 JPO heavy maintenance manager.
“Not only will this project return a combat asset back to the warfighter,” Santos said in a 2023 statement, “but it opens the door for repairing future mishap aircraft using tooling, equipment, techniques, and knowledge that has been developed.”
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