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Editors Note: Our initial issue was intended to be part farce, part parody, hopefully amusing.  However, we have noticed a real ignorance of aircraft costs.  We are not attacking or defending Trump's decision.  We are not attempting to justify the cost.  We simply would like to explain why the price tag for a replacement for Air Force One is so high.

Why is Air Force One so expensive to replace?

1.  It is a government aircraft.
    a. It must go through the procurement process.  This requires specifications down to every nut, bolt, washer, and rivet.
    b.  Is is a competitive bid or single source?  If competitive, then copies of the specifications are reproduced for each bidder.
    c.  Is it one of a kind or are multiples being made?  Economies of scale.
    d. Can it be based on current production aircraft?  In this case, Boeing 747s are no longer in production.  We will revisit this later.
    e.  Can off-the-shelf systems be used?  Are there special equipment requirements?  The short answer is yes and yes.
    f.  How much will need to be sub-contracted out?
    g. Are there upgrades from the previous design?
There are many, many more details such as:
  Is the original producer of the aircraft going to build the replacement?  If not, the government buys back the design documents and drawings, and then gives, yes, gives them to the new contractor.
  Any machinery, dies, equipment required still available?  This will also be revisited.

2.  Materials necessary to build an airframe, alone, are expensive.  One cannot go down to Juanita's Metals to buy sheet aluminum or Bob's Hardware for nuts, bolts, washers and rivets.
    a.  Ribs, spars, stringers are cast and machined aluminum parts.  Are there existing models, molds and who owns them?
    b.  Aircraft wiring can't be bought at Helmut' Electronics.  In most instances, there is special purpose wiring used, depending on system, making it very expensive.
   c.  Air Force One is a special purpose aircraft.  Interior appointments are pretty much custom.

3.  Systems.  Propulsion, Hydraulics, Fuel, Electrical, Avionics, Communications, Special Requirements
    a.  Are newer engines being used?  Will this require modifications to the mounts, wing structure?
    b.  Redundancy of hydraulic systems?
    c.   New mandates on type of fuel used?  Impact on fuel cell composition.  Lot's of trivial stuff involved.
    d.  Power production, distribution, redundancy for aircraft flight and cabin requirements.
    e.  Avionics typically are a cross between off-the-shelf and the latest and greatest.
    f.  Communications for the flight crew and the folks in the cabin.  Lot's of specialty stuff.  Heavily encrypted in some cases.
    g.  The specialty stuff could be anything from medical equipment, galley, and things best left to the imagination.

4.  Assembly.  This requires an assembly location.  People to put the parts together.  Jigs, tools, etc.
    a.  Will the assembly location require security?  You, betcha!
    b.  Will the personal require security clearances?
    c.  Training of personnel required?
    d.   Are there existing jigs?  Any specialty tools required?
    e.  Delivery and security of sub-contracted parts.

5.  Management.  Milestone and workflow.  Quality assurance. Coordination with the government.

6. Miscellaneous.

This is by no means an exhaustive list.  These are just some of the highlights  One last and very important point:
Airplanes are like Bentleys.  Some parts and components are put together on assembly lines.  For the most part, they are hand assembled.  No two aircraft are exactly the same.