The "triple-seven" will be the most technically advanced aircraft to date from Boeing, designed almost entirely by computer. This first hour covers the pioneering methods used by Boeing's aviation designers and engineers - a group that is part of more than 10,000 people involved in the project.
Late design changes may threaten the delivery of major components - from the rudder being made in Australia, to the doors, wing components and fuselage sections in Japan. The drama builds as Boeing tries to bring together four million parts, from several countries, to build the 777.
Engine manufactures Pratt & Whitney are racing toward their certification deadline. Dramatic footage of bird-strike, "blade-out" and high-speed-taxi tests captures the last stages of plane-making before the 777 actually leaves the ground.
One year of flight tests begins for the 777. Boeing must ensure that the plane can survive extreme conditions. Testing culminates in a test called "The Big One." The plane must withstand maximum braking at its heaviest weight, without the 3,000 degree heat from the brakes setting the plane on fire.
It is six months before Boeing must deliver the first 777 to United Airlines. A whole plane is tested to destruction, to measure the amount of force the wings can take. The plane is flown on a mock airline schedule for reliability testing. United Airlines transfers $100 million, and the inaugural flight of the 777 takes off.
