“This was a significant challenge, as it was the first attempt at removing F-35 wings as part of a concept demonstration,” said Matt Trodden, Aircraft Crash Recovery Lead Engineer for the F-35 Joint Program Office (JPO). This ancient procedure was undertaken to save a Republic of Korea Air Force (ROKAF) F-35A stealth jet, badly damaged in a bird collision in January 2022. The incident compelled the emergency belly landing at Seosan Air Base, severely damaging the aircraft, with nearly 300 components damaged. The cost of repair was more than $100 million, and it was financially not viable to put the jet in operational condition once again. A strategic decision was therefore taken to modify the aircraft into a maintenance training facility for the ROKAF staff.
The innovative solution to the logistical issue of transporting the damaged F-35A called for its wing removal and subsequent reinstallation. This was inspired by the earlier “Frankenjet” project, where two crashed F-35 jets were combined into a fresh flyable aircraft. The successful execution of the wing removal and replacement process has now also been incorporated into the F-35 program’s routine heavy maintenance, repair, and reuse practice. This innovation not only demonstrates the feasibility of full wing replacement but also sets the stage for future repairs and global training programs.
The cooperative process of dropping the F-35A’s wings had a multicultural group with members from Lockheed Martin, the U.S. Air Force’s 309th Expeditionary Deployed Maintenance Squadron, the U.S. Navy’s Forward Deployed Combat Repair and Fleet Readiness Center Southeast, and the ROKAF Logistics Command. The process lasted several weeks shy of the deadline, showcasing the effectiveness of the group and the workability of the process. This project’s success proves the viability of low-cost salvage missions, which can readily replace the cost of an F-35 loss, the A model being worth over $80 million.
The overland movement of the wingless F-35A from Seosan to Cheongju Air Base, roughly 60 miles away, was no easy feat. The 35-foot wingspan of the aircraft posed significant hindrances to overland movement, particularly with the two-lane highway route being so constrained. Being able to remove the wings allowed for a more cost-effective and safer transfer, avoiding the high cost and feasibility issues pertaining to other options such as airlifting.
The ROKAF decision to reutilize the scrapped F-35A as a training aircraft is an example of their general drive to maximize maintenance capability and minimize expenses. The action not only conserves precious resources, but it also provides ROKAF crews with hands-on experience in advanced maintenance techniques. Adding wing removal and replacement processes to the F-35 sustainment program further proves the adaptability and strength of modern military aviation technology.
As South Korea continues to add more F-35s to its fleet, with plans to acquire 20 more by the year 2028, the learning experience derived from the project will be invaluable. Having the ability to recover and reuse crashed aircraft efficiently will be crucial to maintaining the ROKAF’s stealth fleet operationally proficient and sustainable. In addition, the innovative work carried out in South Korea provides a template for other countries flying the F-35, providing insights into cutting-edge maintenance solutions which can be shared worldwide.
The success of the wing removal and replacement program not only attests to the technical proficiency of the responsible teams but also to the need for collaboration and innovation in solving intricate engineering issues. As the F-35 program advances, the lessons of this experience will definitely guide the ongoing development of advanced maintenance and repair capabilities, ensuring the future viability of this advanced aircraft.
