I think there are a number of people who did something similar this year:
Started at 6AM at SFO:
SFO-SEA-PDX-SFO-KOA-[redeye1]-SFO-lax-san-ord-[redeye2]-gru-[redeye3]-iad-ewr, arriving at EWR around 10AM on day 3, and I didn't go to sleep until the end of day 3.
Total time not sleeping in a bed on the ground: around 90 hours. It's not that I didn't sleep, I actually slept quite well, just on the plane -- actually on many planes. After some point you just pass out wherever you are :).

Can an AA flyer play?:D

FRA-DFW-LAS-LAX-BOS-LAX-BOS. 14,531 miles and left the secure area for about 20 minutes after clearing customs in DFW.

Also did MTS-JNB-LHR-FRA-ORD-SAT, which covered 12,006 miles.

My outbound to HKG last year was slightly overboard, taking advantage of the $550 LAX-HKG AC fare and the $7 DEN-TVC mistake:

YYC-DEN-PHX-DEN-PDX-ORD-TVC-ORD-SLC-DEN-LAX-YYZ-HKG

Total wheels off the ground time was 42:36, not counting the layovers. It was 17,747 mi.

I just worked out the math, and layovers added up to 19:49, so total time from wheels up in YYC to wheels down in HKG was 62:25.

Paging hunttk, who in July flew HKG-IST-LAX-IST-HKG-IST-LAX-IST-HKG-IST-LAX-IST-HKG-IST-LAX, with one night in a hotel in IST. I should know because I booked the same trip with him until sanity prevailed and I canceled the whole thing when I realized it would be almost 2 straight weeks of flying! :eek: And actually, hunttk's trip might have been even longer because I can't remember if he overnighted in HKG after his positioning flight or in LAX before returning to YYZ.

Wow. I immediately had to go to Great Circle Mapper of course to calculate how many miles that would be ;) 82,992 I hope it was a good deal :D

my longest stretch at once was BOS-LAX-DFW-JFK-LHR-BOM-JNB; don't remember the total times anymore

YYC-YUL-CAN-YYZ-YVR-SFO-ICN-PEK-BKK-SIN-FRA-ZRH-YUL-YYZ-YVR-YYC

in 7 days...all in F (mini RTW) and J. 3 days on the beach in CAN, overnight in ICN, 1 night in BKK. Have never been so glad to see my own bed at the end.

WOW!! I think we have a winner if you can total up the hours of the above trip between beds on the ground. Remember: once you get into a bed (on the ground), you are out of the game!

ALSO can you tell us WHY the above trip was taken?

I'm about to do: HKG-IST-LAX-IST-HKG-ICN-FRA without a hotel break later this week. Glad the new TKY IST lounge is now open, the TG HKG lounge has a pair of Panasonic massage chairs, and that the OZ ICN First Class lounge is one of the better places to pass a few hours between connections.

Lax-ord-yul-lhr-sin-syd

My longest trip was: JOH-AMS-VIE-KUL-PHUKET 2 hours stop in amsterdam, 2 hours stop in vienna and 3 hours stop in kuala lumpur and after that journey i got a Tromphosis.

I think most of you are focusing on time en-route only. But taking the question more liberally, I recently left YOW on a Sun evening and returned on Thurs evening without a hotel night anywhere en-route. Total about 94 hours.

Sun night YOW-LHR AC redeye, followed by meetings in London, then Mon night BA redeye to middle east, meetings on Tuesday. Etihad redeye to Beijing, conference presentation on Wed. The AC late pm flight to Vancouver, brief walk in Stanley Park to get some fresh air on a gorgeous late summer evening, then redeye to Montreal. Thurs meetings in Montreal, Thurs eve bus to Ottawa and home. Fortunately all in flat-bed J, with plentiful use of lounge showers, except the dinky AC YVR-YUL in domestic J and the 2 hours on the bus from Montreal to Ottawa. Was surprisingly livable though I hope I won't have to repeat anytime soon...

i think my max was 34 hours..... due to a 13 hour transit in SFO..........

My 2 longest ones are:

AC/BD:SYD-YVR-LHR-EDI -at 30+ odd hours with transits

Also a real interesting one MH (Malaysian Airlines):SYD-BNE-KUL-JNB-CPT-EZE all in one go and thankfully all in J at over 40 hours and lots of satay had!

SYD/YYZ