Boeing 747 worth $270,000,000 broken down and reassembled in painstaking process that's captured on film for first ever time
Published on Jan 11, 2026 at 12:44 AM (UTC+4)
by Henry Kelsall
Last updated on Jan 08, 2026 at 9:39 PM (UTC+4)
Edited by
Amelia Jean Hershman-Jones
In this first-of-its-kind and rare footage, a Boeing 747 airliner worth $270 million was stripped down into its parts before reassembly for flight.
The giant aircraft was the subject of an On The Move documentary several years ago, and it was being moved to Cardiff in Wales in order to recertify for flight.
Airplanes like the 747 are designed to be disassembled and then put back into service as part of their maintenance regime.
As the documentary showed, it is a complex process, and one that takes a lot of precision and care.
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Why the Boeing 747 was being broken down
The airplane was residing in London, but needed to be relocated to Cardiff for recertification for flight.
This formed part of its regular maintenance programme.
After so many flight hours, an aircraft needs to be stripped down, renovated, and any expired parts replaced.
This particular documentary actually marked the first time British Airways allowed the process to be filmed.
The airline was the operator of this particular 747.
Remarkably, the scheduled completion date for the overhaul was also a day the airliner was booked to fly again.
As the documentary showed, the aircraft is stripped right down to its basic components.
Even the interior was stripped out, allowing it to be reupholstered and fully renovated.
Why an aircraft needs breaking down and reassembling
There are multiple reasons why an aircraft like this Boeing 747 needs to be renovated in this manner.
Over time, parts can expire and will need replacing.
It would be dangerous to fly the aircraft with old and worn-out parts.
Parts such as the engines can be refurbished, and the structural integrity of the aircraft can be checked.
Plus, as the documentary showed, it’s a chance to refresh the cabin and seats for the passengers.
If you are on an airliner for a long period of time, you will want to be as comfortable as possible.
The latter part of the video shows the airliner being tested on the ground before it takes to the skies once more.
The renovation would have allowed the aircraft to continue flying for many years to come.
Boeing 747 Timeline
1966 (April): Program Launch Pan American World Airways places the first order for 25 aircraft, effectively launching the program.
1968 (September 30): First Rollout The first 747 is rolled out of the custom-built assembly plant in Everett, Washington.
1969 (February 9): First Flight The 747 makes its maiden test flight, piloted by Jack Waddell, Brien Wygle, and Jess Wallick.
1970 (January 22): Commercial Debut Pan Am operates the first commercial jumbo jet service, flying from New York (JFK) to London (Heathrow).
1989 (February 9): The 747-400 Era The most popular variant, the 747-400, enters service with Northwest Airlines, featuring winglets and a glass cockpit.
2005 (November 14): 747-8 Launch Boeing launches the final generation, the 747-8, incorporating technology from the 787 Dreamliner.
2011 (October 12): 747-8 Service Entry The first 747-8 (a freighter version) is delivered to Cargolux; the passenger version follows in 2012 with Lufthansa.
2023 (January 31): End of Production Boeing delivers the final 747 (a freighter) to Atlas Air, ending a 54-year production run with 1,574 aircraft built.
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Henry is a content writer with nearly ten years experience, having written for various publications since 2017. Qualifying with a Sports Journalism degree from Staffordshire University, Henry loves all things automotive but has a particular soft spot for classic Japanese cars and anything Lancia. He also has a curious passion for steam locomotives.
