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IAI begins Boeing 777-300ER-to-777-300ERSF conversions in North America
Israel Aerospace Industries, Ascent Aviation Services and World Star Aviation announced the start of Boeing 777-300ER passenger-to-freighter conversions at Marana, Arizona, with the first World Star aircraft now at the site.
The companies announced the start of Boeing 777-300ERSF conversion work at Ascent's expanded Pinal Air Park campus in Marana, Arizona. The first aircraft is an 18-year-old Boeing 777-300ER registered N755WS (MSN 33755), previously operated by EVA Air, which has arrived for conversion. Marana will serve as the North American conversion site for IAI's programme.
IAI launched the 777-300ERSF programme, known as Big Twin, in 2019 with GECAS, which later became part of AerCap. The programme received certification from US and Israeli aviation authorities in September 2025. As of October 2026, IAI had completed and delivered 11 converted aircraft; customers and operators include Kalitta Air, Fly Meta, Challenge Group and Emirates SkyCargo, with Kalitta Air receiving seven aircraft. In July 2026, IAI reported five additional aircraft undergoing conversion.
Ascent will operate two parallel 777-300ERSF conversion lines at Marana. Two new 90,000-square-foot widebody hangars have been completed, and a $70 million investment tripled hangar capacity at the site. IAI is also expanding its conversion network through partnerships with Sharp Technics K in Incheon and Etihad Engineering in Abu Dhabi. A September 2025 agreement with World Star Aviation covered one conversion with an option for a second.
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