Mammoth Freighters is building up toward five Boeing 777 passenger-to-freighter conversion lines at its Aspire MRO facility at Fort Worth Alliance Airport.
This comes after the conversion specialist shored up 35 firm orders for both its 777-200LRMF and 777-300ERMF freighters while planning a second conversion facility in the UK.
“We have three aircraft in work right now. Two aircraft are 777-200LRs for Cargojet, while the third aircraft is one of nine Jetran -200LR’s headed to DHL,” says Brian McCarthy, vice president of marketing and sales at Mammoth Freighters.
“Additionally, Mammoth’s first 777-300ERMF conversion is nearing completion of all its pre-modification flight tests," says McCarthy. "Once, flight tests are completed, we aim to induct the -300ERMF in early October.”
Mammoth expects the 777-200LRMF to enter service at the end of the second quarter 2024, with the 777-300ERMF following six months afterward.
The first 777-300ERMF is part of a six aircraft deal with AviaAM Leasing, part of Avia Solutions Group, which is also the launch customer for the aircraft type. Jetran has multiple orders for Mammoth's freighters, including nine 777-200LRs earmarked for DHL to operate on an ACMI basis after completion.
McCarthy says Mammoth Freighters will “walk before it can run” toward five conversion lines at its Fort Worth site. Nevertheless, plans have accelerated due to availability of parts and floor beams for all aircraft.
“The high availability of parts together with abundant hangar facilities allows us to advance production on all the early aircraft while being mindful of the regulatory hurdles and certification efforts ahead,” McCarthy adds.
Mammoth Freighters is the only 777 cargo converter that is currently developing supplemental type certificates for both 777-200LR and 777-300ER platforms. Competitors Israel Aerospace Industries and Kansas Modification Center are currently focusing on the 777-300ER conversions.
The 777-200LRMF has a gross payload of 233,000 lb., making it comparable to the 777F factory freighter. The 777-300ERMF has 25% more cargo volume than the factory freighter and will have gross payload of 220,000 lb.
“The baseline testing for the -200LR is now complete. There is a requirement to complete noise testing on the -300ER because it is a bigger aircraft,” says McCarthy. “The engines and the flight controls are all the same on both platforms. They have the exact same wing, pylon and center box. The fundamental geometry difference is that the horizontal stabilizer on the -200LR is slightly larger.
Mammoth's second conversion facility will be located at Manchester Airport in the UK, where it expects to run a minimum of two conversion lines. It is believed that the facility will help increase Mammoth’s footprint in the region and improve customer service and spares levels with European and Middle Eastern operators.
“The Manchester site will become operational next year. It will be located within the ex-Thomas Cook hangar at the airport. The large facility makes it very well suited for 777 P2F conversions because it is possible to position two 777s in each corner with room to spare,” McCarthy adds. “The STS Aviation Group will oversee the conversions and has all its manpower in place."
The FAA has accepted Mammoth's program specific certification plan. Mammoth expects a 777-200/300 freighter conversion will take 5.5 months to complete after a steady state of production is achieved late in 2026, and subject to certification timing.
