Boeing Begins Major Assembly on 777-8 Freighter: Spar Production Underway

Boeing has formally begun the primary assembly process of the 777‑8 Freighter with the drilling of the first hole into its spar structure at the Everett, Washington facility. The spar — a 108-foot composite beam — is critical to the wing’s strength and marks the start of major airframe construction.

Approximately 100 team members from the 777X Composite Spar Shop celebrated the milestone, with Casey McDowell initiating the process. “You don’t forget these moments… Having our team together as we got underway on this airplane was special,” said McDowell.

Meanwhile, automation manager Robin Thorning, with a Boeing legacy spanning generations, reflected on his journey from the first 777 to today’s cutting-edge freighter, noting it as a “once-in-a-lifetime opportunity.”

This progress comes after Boeing began building the first wing skins and panels at its Composite Wing Center just days earlier. Each 777‑8 Freighter wing requires two spars weighing 2,500 pounds each and uses 392 miles of carbon fiber tape—enough to stretch from Everett to Montana—highlighting the scale and innovation behind the operation.

Boeing has already accumulated 59 orders for the 777‑8 Freighter since the program launch in 2022, with delivery of the first aircraft targeted for 2028. Jason Clark, VP and GM of the 777/777X program, praised the workforce: “You are leading the way as we introduce our newest freighter into our production system.”

The 777‑8 Freighter is the cargo member of Boeing’s new 777X family, alongside the 777‑9 and 777‑8 passenger variants. It promises to be the most efficient twin-engine freighter in operation — combining payload capability with fuel economy and technological advancement.

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Ricardo Meier

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