Today’s episode of
F A C T S is made possible by
@Ravofox. The first five readers to use code
MISCHIEF will get a three-month subscription for their own
@Ravofox for just $9.95.
In the early hours of January 22, 1970, 355 people depart New York’s JFK International for Heathrow. But this is unlike any transatlantic crossing before it – because all 355 passengers and crew are on board the same aircraft, a Pan American jet named
Clipper Young America. And in six hours and forty-three minutes, the first Boeing 747 in service would land at Heathrow and change commercial aviation forever.
Clipper Young America (later renamed
Clipper Victor) would usher in a new era of travel, because Pan Am would prove that Boeing’s new 747 – the first ever widebody airliner – had a place in the skies. And for decades, it would be the largest plane to ever fly. Welcome to
Double Decker – a two-part look at the two largest jet airliners in existence.
In the 1950s, Britain introduced the world’s first jet airliner, the DeHavilland Comet. But while Europe was the first, they quickly lost ground to American giants like Douglas and Boeing, who were able to make more reliable aircraft while getting better range. Despite beating the Americans into service by six years, the Boeing 707’s instant popularity would give it the title of harbinger of the jet age. And without the crowded competition that the literal dozens of manufacturers had to fight in Europe, Boeing and Douglas would hold over 80% of the airliner market by the 1960s.
Boeing’s early jet lineup was effectively a money printer. At 1,019 produced, the 707 and 727 would dwarf combined European airliner production. The 707 could take the DeHavilland Comet or Sud Aviation Caravelle, and best all of their vital stats such as passenger capacity or range by double or triple, depending on the configuration. It wasn’t the first, but it was an untouchable powerhouse. And it gave airlines like Pan Am a global reach, able to fly from Honolulu to London non-stop.
Absolute legend Tex Johnson on the Boeing 707
But Pan Am’s founder Mr. Juan Trippe was an ambitious man. The forerunners of the era, the 707 and Douglas DC-8 already had the highest passenger capacities. Mr. Trippe wasn’t terribly interested in having the largest capacity for the sake of capacity, but rather to ease congestion. Pan Am had introduced a new “Rainbow Class” in 1952 (the predecessor to modern economy fare), making commercial air travel accessible to the American middle class. And with increased demand, came increased congestion. By having fewer aircraft at higher capacity, the logic followed that congestion would drop. So Mr. Trippe turned to Boeing, hoping to leverage his position as Boeing’s largest customer.
Before Pan Am came knocking in Seattle, Boeing was already embroiled in a bitter fight with Lockheed for the US Air Force’s CX-HLS (Heavy Logistics System) contract. The Lockheed C-141 Starlifter introduced in 1962, at the time the largest military aircraft, was only considered something of a stopgap measure by the US military to replace their dated propeller transports. Despite losing the contract to Lockheed and their C-5 Galaxy, Boeing turned around to find Mr. Trippe patiently waiting.
Boeing assigned engineer Joe Sutter from their next money printing 737 project in 1965 to consult with Pan Am on their newest request. Pre-designated the 747 based on Boeing’s naming convention, Sutter focused the 747’s design on cargo capacity. If we recall, the Boeing 2707 was starting to take shape around this time, and the prevailing theory was that the 747 would be a temporary step before supersonic travel. So to meet Pan Am’s needs (and give Boeing a fallback scenario if passenger variants declined in popularity), this new 747 was designed around a standard 8’x8’x20’/40’ container. Higher passenger capacity would just…happen.
To make the most possible cargo space, the 747 borrowed elements from Boeing’s failed HLS bid. The cockpit was situated on a second deck, and freighter variants housed a swinging nose door for maximum cargo access. The second deck was originally intended to be full-length, but the lack of usefulness for the upper deck in terms of cargo made Boeing cut the upper deck’s length to give the 747 its distinctive hump. But with the upper deck not certified for passenger use, early 747s ended up featuring the space as a bar or lounge.
The first ever 747 in the Paine Field assembly - the largest building ever built by volume
After about a year of consultations, Pan Am was satisfied with this new design. And in 1966, they ordered 25 747-121 aircraft for about $525M USD (almost $4.2 Bn today). Because Pan Am commissioned the design (and because Pan Am was Boeing’s largest customer), Boeing crunched development time to just 28 months. But the 747 project wasn’t just massive, it was…er…massive. Boeing didn’t have a facility large enough to get the 747 built. With a steady flow of cash coming in from 707 and 727 sales, Boeing did what any sensible company would do and bought a disused military base (Paine Field) near Everett, WA.
My current opinions on the company aside, I respect the extraordinary lengths Boeing went through to get the 747 built. Despite starting the project with a firm order and guaranteed sales, Boeing didn’t have the infrastructure in place. After buying Paine Field, the company worked with nearly Japanese efficiency to level the old buildings and construct the new factory, all while developing and engineering the plane in 67% of their normal timeline. I say nearly Japanese efficiency because by the time first mockup was built, the factory roof above it still wasn’t finished.
By now, you might be wondering “if Boeing’s factory wasn’t big enough, how will it even fit at other airports?” You’d be among the several others that weren’t Pan Am or Boeing to ask that question. The 747’s wingspan was just two inches shy of being 65 feet wider than the 707. It was also over 30 feet longer, and more importantly nearly
triple the maximum takeoff weight (MTOW) of the 707 (700,000 lbs vs 257,340 lbs). Concerns were immediately voiced about how the 747 would even fit at airports like JFK or Heathrow. To make sure their newest toy would be operable from their home base, Pan Am built a new terminal 3 (which they called the Pan Am Worldport), specifically to accommodate the 747. Remember, these guys were the largest airline for the time. They had a
lot of money to burn.
Pan Am's Worldport (Terminal 3) at JFK
Speaking of money to burn, Boeing
really didn’t have any. Even though the company would enter the decade on strong sales and leave it launching several moneymakers, the 747 project was a massive financial drain. The 2707 had the benefit of Congressional backing, and the new 737 that the company desperately needed could skimp on costs by borrowing most of its tech from the even older 727. But the 747 was new territory without government funding, and Pan Am’s $525M order wouldn’t be nearly enough to cover development costs, which totaled approximately $1Bn ($7.05 Bn today), on top of which Boeing owed
another $1Bn from Paine Field’s construction and other debts. To stay afloat, Boeing needed a winner. And they’d have less time than they’d think.