en.Wedoany.com Reported - Ascent Aviation Services has opened two new widebody hangars in Marana, Arizona, as a surge of Spirit Airlines aircraft and new investments in heavy maintenance operations keep the facility at full capacity. The first Boeing 777-300ER passenger-to-freighter (P2F) conversion is set to begin on September 1.

Ascent opened two 90,000-square-foot widebody hangars in December 2025 to support a 15-year contract with Israel Aerospace Industries (IAI) for 777-300ER P2F conversions. The approximately $100 million investment, backed by Monroe Capital, covers tooling, training, and hiring. The new hangars increase capacity at the Marana base by 200%.

Ascent CEO David Querio said the hangars have been extremely busy since opening, with a full workload. The first hangar will be fully dedicated to P2F conversions once the IAI program launches, but the timing for switching the second hangar has not yet been determined, as the company continues to meet other customer demands.

Scott Diaz, Senior Vice President of Sales and Marketing at Ascent, said the company needs to balance labor resources to meet customer demands while handling the influx of Spirit aircraft. Ascent has received nearly 100 Spirit aircraft, some of which have already departed, with a few remaining to be received. Most aircraft are in temporary storage while awaiting remarketing, and some have received letters of intent from buyers, which the company will push into the next phase.

Querio noted that at least one Spirit aircraft is being dismantled. Aircraft acquired from the airline may turn over faster, as they were originally operational and remain in flying condition. However, the first dozens of aircraft that arrived were previously grounded due to issues with Pratt & Whitney's geared turbofan engines and may need to be stored for several years awaiting engine returns.

Tim McGuire, President and Chief Operating Officer of Ascent, said the influx of Spirit aircraft has significantly boosted the company's heavy maintenance line operations for about the next year. A side effect of Spirit's collapse has been a source of talent, and Ascent continues to hire, aiming to add 300 to 400 positions to support P2F conversions and heavy maintenance growth.

The first 777-300ER conversion is expected to take six to seven months. Ascent plans to launch a second conversion line next year. Querio said the company will run two lines consecutively with staggered starts, transferring expertise from one aircraft to another at full capacity after mastering the learning curve. Once the sixth aircraft is in operation, the company will deliver six aircraft per year. In total, Ascent expects to perform more than 60 to 70 P2F conversions for IAI.

To prepare for the conversions, Ascent launched an eight-week structural apprenticeship program in January 2024, pairing students with structural technicians for hands-on experience at the Marana and IAI Tel Aviv facilities. Each cohort consists of 10 to 12 students, and about five cohorts have been completed. Some of the first graduates have already become team leaders.

Ascent has also obtained new certifications to support P2F conversions. It has received ISO 9001 certification and is applying for AS9100 certification at IAI's request. Additionally, it is pursuing certification from the Civil Aviation Administration of China (CAAC) to support conversions of aircraft registered in China.

Querio's goal is to grow billable revenue by more than 50% between 2025 and 2028, driven by new customers and continued investment. Ascent is expanding its landing gear capabilities, setting up new workshops for Airbus A320 series and Boeing 737 aircraft to reduce outsourcing and shorten turnaround times. It is also continuing to invest in A330 capabilities, aiming to become a full-service center.

Ascent is also building additional support facilities, including back shops and customer offices, to modernize some of the remaining World War II-era structures. One of these should be completed within a month, with two more finished by the end of the year.

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