Mammoth achieves certification for 777-200LR converted freighter, eyes partner in China

US aircraft conversion specialist Mammoth Freighters has received Federal Aviation Administration certification for its cargo-modified 777-200LR, a milestone coming as the firm accelerates production and plots global expansion, including in China.

Mammoth, which is among several companies developing passenger-to-freighter-converted 777s, disclosed the approval on 8 April, saying it is now poised to deliver the first 777-200LRMF (Long Range Mammoth Freighter).

Founded in 2000, Mammoth is also developing the 777-300ERMF, a cargo modified -300ER variant the company expects will receive certification before year-end.

“Approval of the 777-200LRMF underscores the strength of our technical approach and our ability to deliver a high-performance freighter that meets the evolving demands of cargo operators worldwide,” says Mammoth chief executive Bill Tarpley.

Mammoth will soon deliver the first 777-200LRMF to launch customer Jetran, a US aviation services and aircraft leasing company that will place the aircraft with Qatar Airways, says Mammoth vice-president of marketing and sales Brian McCarthy.

Boeing only produced about 60 777-200LRs, and some — including government-operated types — are unlikely candidates for conversion.

But McCarthy predicts Mammoth will “convert the majority of the remaining [777-200LRs] on the world marketplace, which is roughly 40-50 aircraft”.

“They are all going to be converted because you can’t get any closer to a factory freighter,” he says, referencing Boeing’s new-build 777F. “It’s very close to a factory [build], without the extra $100 million… I just wish we had hundreds more [777-200LRs].”

Mammoth already has agreements to modify roughly 20 more 777-200LRs for Jetran, which plans to deliver two to Qatar (including the first delivery) and others to DHL and Ethiopian Airlines.

“From the outset, we have had strong confidence in the Mammoth engineering team and their vision for the programme,” says Jetran chief executive Jordan Jaffe. “The aircraft’s quality and technical execution have met our high expectations and reflect the strength of the underlying design.”

Mammoth’s 777-200LRMF has 104,800kg (231,000lb) of payload and 4,800nm (8,890km) of range. Boeing’s 777F has similar specifications.

Aspire MRO, Mammoth’s corporate affiliate, is performing the programme’s initial conversions on five lines at its Fort Worth facility, a former American Airlines site. Mammoth also produces the 777-200LRMF’s cargo doors and some structures in Fort Worth.

Partner STS Aviation, a UK MRO firm, also has two active 777-200LRMF conversion lines. With the two sites, Mammoth has seven lines operating, each capable of completing at least two conversions annually, McCarthy says.

More expansion is in the works.

“We have intentions of meeting the Chinese market in China,” McCarthy adds, noting Mammoth is now considering a “group of” Chinese MRO shops as possible partners. “By the end of this year, we will have an airplane headed in that direction.”

Mammoth is meanwhile close to achieving certification for its 777-300ERMF.

“That prototype will be finished in late May and start ground- and flight-testing at that time,” says McCarthy.

“The -200LR was pacing the -300ER’s certification,” he adds. “A lot of the testing for the -300 is going to be very academic because the FAA has recognised [the types’ similarities].”

Mammoth’s 777-300ERMF will have 98,000kg of payload and 4,800nm of range, it says.

“For higher-density cargo operators, the -200LR is a marvelous airplane, and for the volume haulers and e-commerce [operators], the -300ER is going to be an absolute workhorse,” McCarthy adds.

AviaAM Leasing, part of Irish-based Avia Solutions Group, is Mammoth’s 777-300ERMF launch customer.

Besides Boeing, Mammoth’s competitors include Israel Aerospace Industries and Kansas Modification Center, both of which offer cargo-converted 777s.

IAI last year received certification for its 777-300ERSF (Special Freighter). Kansas Modification is now seeking regulatory approval for its 777-300ERCF (Converted Freighter).