Israel Aerospace Industries (IAI) has completed the Fuselage Cut out for the main-deck cargo door of its prototype Boeing 777-300ER freighter - the BIG TWIN !

• Israel Aerospace Industries (IAI) is Converting the 1st Boeing 777-300ERSF in the world In partnership with GECAS.
• IAI has begun the structural modification phase of the conversion, which will take 130 days.
• IAI Aviation Group has reached the milestone moment in the conversion of its first Boeing 777-300ER aircraft by cutting an opening in the hull to install a cargo door.

It all started in the month of August 2021, when GECAS and IAI came together for the Conversion of a B777 300ER aircraft at IAI's Facility after identifying a Launch Customer.

Kalitta Air is the launch customer and already leasing three of the first Big Twin freighters to be converted , the scheduled and on-demand charter operator has contracted to lease two additional B777 300ERSF from GECAS.

Now, as of today , a definite progress to the conversion process can be seen , when the IAI has already cut the part of a Fuselage (hull), rather we can call it a Shell (Skin + Frames + Stringers), that will be used as the main-deck cargo door opening for the prototype Boeing 777-300ER freighter - the BIG TWIN !

As it is the main cargo door , the removed Fuselage part of the the aircraft was huge, rather a cut out of is seven meters long (Longitudinal)  and a third of the aircraft’s circumferencial crossection.

The Fuselage cutting comes shortly after the beginning of the aircraft’s structural modification in the month of August , a process that will take approximately 130 days , the company added.

At the end of this time (TAT) , the commercial passenger aircraft (B777-300ER) will be converted into a cargo aircraft (B777 300ERSF).

The cargo conversion process includes,

• modifying the aircraft structure,
• including the installation of a new cargo door,
• replacing and reinforcing the cabin floor,
• installing reinforcements in the cargo door area and
• adapting the electric network and other systems to enable a safe and convenient operation.

In addition, this process includes receiving certification for the converted aircraft from the Local Civilian Aviation Authority and the US Federal Aviation Administration (FAA).

“Completing the 777-300ER conversion on time and according to the planned schedule is at the top of the Aviation Group’s priorities. Today, we mark an exciting step in the prototype’s conversion,” said of IAI’s Aviation Group executive VP and general manager Yossi Melamed.

“Cutting the aircraft’s haul for the new cargo door is a prime example, reflective of the cargo conversions at IAI, which significantly advances our development process for this conversion. This step will allow us, in the near future and with increased confidence, to establish more conversion lines all over the world in order to provide services to the dozens of existing orders and to many more expected orders to come.”