Boeing’s bold bid to build the next-generation aerial refueling tanker on a fixed-price contract seemed like a sure bet—leveraging the proven 767 airliner for low-risk development. Instead, the KC-46 Pegasus program has cost the company more than $7 billion in losses, plagued by relentless technical failures, delivery delays, quality scandals, and ongoing operational restrictions that persist into late 2025.This investigative documentary uncovers the full story: from the aggressive 2011 contract win against Airbus, through the Remote Vision System disaster, stiff boom issues causing millions in damage (including a July 2025 detachment incident), structural cracks halting production, and persistent Category 1 deficiencies. With the 100th KC-46 delivered in December 2025 and RVS 2.0 fixes now delayed to summer 2027, it exposes how underbidding and integration complexities turned a vital Air Force modernization into Boeing’s costliest defense nightmare.