787 exceeds 200 flight hours; 18th 787 starts final assembly

As Boeing continues to pile on 787 flight hours, it has also started final assembly of the 18th 787 destined for ANA.

Dreamliner 1 continues to rack up the most flight hours and mos flights with 39 flights that has accumulated almost 138 flight hours through March1, 2010. The 787 test fleet has accumulated almost 210 flight hours.

Boeing also started assembly of Dreamliner 18 after line move yesterday. Look for Boeing to start assembly on LN 19 and LN 20 (I don't have the ZA numbers yet). The later aircraft is an important milestone as it is a new block point that incorporates weight saving measures in an effort to lower the weight of the airplane. The 787-8 is still overweight but Boeing still hopes to find further areas where they can take out weight as the flight testing progress.

Because of the addition of ZA004 to the test program, Boeing will have valuable data to finalize the design of the 787-9 which is the stretched version of the 787-8. The -9's wing will be the same as that of the 787-8 but Boeing is hoping that test flight information from ZA004 flight tests will yield important information when designing the 787-9. Flightblogger has a blog post up tonight describing the 787-9 progress to date. In the article he says that the first 787-9 will be designated ZB001 but will be LN 139.

Flightblogger: Driving Forward on the 787-9 design

Guy Norris also put up an update on the 787 flight testing as well as the 747-8 flight testing. Guy sasy that ZA001 has flown 11 flutter tests (now 12) while ZA002 continues with stability and control flight testing. ZA003 should also start the run up to gauntlet testing next week.

Guy Norris : 787 and 747 test update

Guy Norris: Final Gauntlet began this morning

According to Guy Norris at Aviation Week. Boeing has started the final gauntlet testing on ZA001 this morning. The testing should take about 2 to 3 days to complete which should coincide with Boeing having the final results from the static tests on the wing.

Guy reports that the gauntlet testing will be done in four blocks with the first block following the testing that would occur during the aircraft's first flight. The other blocks will test failure modes with the last block going through a full first flight in realistic conditions.

Guy Norris: 787 Countdown to first flight (resumed) Part 3

Flightblogger: 787 First Flight Date's a Moving Target

Well the title sums it all up. I even heard a date of Dec. 12th though I really think that date is not realistic. One pattern is emerging: the date is going to be between Dec. 14th and Dec. 22nd and Boeing is marching towards that date.

Flightblogger reported that Boeing performed software checks as well as testing the thrust reversers. The final gauntlet testing is still schedule for next week and ZA002 is inside going through some final reassembly activities as well as getting it's fuel tanks washed out.

Also Matt Cawby reported on his blog that Boeing conducted VHF radio checks on the same frequency that was used for the taxi tests. The nose section for LN14 (Dreamliner 14) was delivered today on the LCF from Spirit Aerosystems.

Flightblogger

Matt Cawby

787 may fly on Dec. 14th

Photo by Liz Matzelle

Sources have told me that Boeing is targeting Dec. 14 at 10AM for the first flight of the 787.

This schedule is dependent on three important tasks being completed:
1. Detailed analysis of wing limit load test
2. Gauntlet testing (presumably done concurrently with the detailed wing load limit analysis)
3. Low/High speed taxi test and rejected take off tests

Sources have also said that ZA001 can start engine runs as early as this week.
ZA002 is not ready to undertake any testing as its fuel tanks are not closed or have had an aqueous wash after the modifications.

The immediate question is can Boeing pull it off so soon? They can in my opinion. When Boeing announced the latest delay, they were one week away from first flight and had completed all the major gauntlet testing and were about to start taxi tests, some of which they did do (low speed). With the potential clearance of the side of body flaw in about 10 days, Boeing would be back to the same spot they were on June 23rd. Boeing can concurrently carry out the detailed analysis of the static tests along with the gauntlet retesting as well as conduct low speed taxi runs up to the point that the detailed analysis is complete during those next 10 days. If it done by Dec. 10th then Boeing can have four days to do high speed taxi runs and rejected take off testing and go immediately into flight test mode on Dec. 14th.

Finally I reported that the 787 and 747-8 would make the first flight on the same day. That has since been disproved and the 747-8F will make it's first flight on Jan. 14th as I had posted earlier.

UPDATE - Flightblogger also is reporting the same news that ZA001 can be flying as early as Dec. 14th weather permitting.

First Flight Countdown Begins for 787

Finally some 787 News

Well after a few weeks without any news of the 787's journey to first flight, Guy Norris at AWST put a posting this evening saying that Boeing is targeting a first flight for late December. Work is still not yet done on ZA001 and there is the validation work yet to be done on ZY997 which is the static test air frame. According to Guy, Boeing hope to get renewed gauntlet testing underway on ZA001 around Thanksgiving time in late November.

Assuming that the FAA and Boeing are in agreement on the fix and pre-flight gauntlet testing goes well, Boeing would be looking at first flight around Christmas time. Stay Tuned!

Late December First Flight Targeted for 787

Also Flightblogger has a great posting on Spirit and its delivery of the nose section of the 787. In his post, Flightblogger is reporting that Spirit will deliver 10 787 sections this year and will restart production of the fuselage barrels later this quarter to prepare for the ramp up to full production.

Spirit to deliver 10 787 shipsets

787 First flight a month away

Boeing: Final Gauntlet Testing started on ZA001

Boeing has confirmed to me that final gauntlet testing has begun on ZA001 and is currently on going. Boeing will have a better idea of when taxi tests will start after the completion of the gauntlet tests. Since tomorrow is a holiday for the US due to the July 4th holiday the test team may elect to continue testing on Friday if it's warranted.

Flightblogger: 787 Intermediate Gauntlet Test Completed

Flightblogger says that Boeing confirmed the successful completion of the intermediate gauntlet tests. Boeing is pretty much set up for the start of final gauntlet testing after the intermediate was completed on Sunday afternoon (June 7th).

Jon also reported that ZA002 completed tests of its navigation system. ZA002 could be on the fuel dock as early as Tuesday for its fueling tests and calibration as well as spooling up its APU for the first time.

Flightblogger: Intermediate gauntlet complete

Guy Norris: Intermeidate Gauntlet Test on ZA001 completed!!

Guy Norris reported this afternoon that Boeing has completed intermediate gauntlet testing on the first 787 today. The results of the intermediate gauntlet testing apparently were better than expected thus eliminating the ened for further blocks of gauntlet testing by Boeing.
The process now moves to a systems test monitoring evaluation which Guy says should pave the way for the start on final gauntlet testing.

Guy's 25th 787 Update.

Guy Norris: Boeing into final aspects of intermediate gauntlet tests

Guy Norris is reporting that intermediate gauntlet testing is entering its final stages with blocks 17 and 18 completed last night and blocks 19 through 21 to be performed today into the night tonight. Blocks 19 and 20 specifically are geared to run through tests that would be performed during first flight. These blocks relate to refining the flight control software during the first flight.

ZA002 will be testing part of the navigation system called the earth reference system (ERS). Hopefully this airplane should be towed out to the fuel dock to go through fueling tests. I believe that ZA002 is still slated to fly about 3 weeks after ZA001. This could put ZA002's first flight around the first week of July.

ZA003 flight crew is undertaking more simulation training in the ITV, specifically on handling smoky situations arising from the forward and aft cargo bulk holds.

Guy's 787 Update #24

ZA001 intermediate gauntlet testing entering the final stages

Both Flightblogger and Guy Norris report that ZA001 is entering the final stages of it's intermediate gauntlet testing with no apparent issues thus far. The stage seems to be setting for the final gauntlet followed by taxi tests.

Both Guy and Jon are reporting that Boeing is on block 14 and block 15 which covers environmental controls and more common core systems (CCS) testing today. On Thursday will see electrical systems tests, as well as pilot conditions tests and a final CCS test which will go into early Friday morning.

ZA002 is progressing through it's factory gauntlet and should be out by the fuel dock to go through the similar fueling tests that ZA001.

Additionally, Jon is reporting that the main fuselage section for ZA100, the first production aircraft for ANA, is being kept at Charleston, SC to finish off work and to ensure that there isn't any travelled work.

Flightblogger June 3rd Report
Guy's 23rd 787 Report

Here's a video from Liz Matzelle of Dreamliner 1 undergoing gauntlet tests on the Boeing ramp:

Simulated Dreamliner Test Flights from Liz Matzelle on Vimeo.

Guy Norris: Intermediate Gauntlet Testing Continues with further block tests

Guy posted that Boeing is still continuing with gauntlet testing and are now up to test blocks 8 through 11 with block 11 expected to be completed by late Tuesday. Boeing does expect to complete intermediate gauntlet by this Wednesday. No word on when final gauntlet will start.

I do expect that ZA002 will go through gauntlet testing as will ZA005 which is the first GEnx airplane. I'm not sure about the other test airplanes but they will eventually go through some period of pre-flight testing before their first flights. I'm still maintaining my prediction for first flight after the Paris Air Show and specifically around June 19th (note: I erroneously put the 9th, duhhh).

Boeing will make it June 18th just to spite me. Just kidding Boeing!

Guy's 22nd 787 post.

Flightblogger: Boeing confirms 787 intermediate gauntlet tests

Flightblogger confirmed that ZA001 has started intermediate gauntlet testing which should be completed by this Friday at the latest. Jon also said that high powered engine runs were conducted on Friday (May 29th) prior to the start of gauntlet testing.
Boeing also confirmed the start of the tests on Randy Tinseth's blog that was posted last night. In his blog, Randy says that they won't expect to put out any more progress reports over the next few days as they're busy getting and analyzing data during this testing. Randy also linked to a great video of the first engine run on ZA001.

Flightblogger posting confirming start of intermediate gauntlet testing.

Randy's Blog: The Gauntlet Begins

Guy Norris: ZA001 to go through 5 testing blocks during early intermediate gauntlet testing

Intermediate gauntlet testing is underway and according to Guy Norris, ZA001 will go through 5 blocks of tests during the early period of intermediate gauntlet testing. Additionally, the start of this testing was slightly delayed for unknown reasons. The five blocks outlines by Guy should be completed by late Sunday night. Of course this is just the start of intermediate gauntlet testing that is expected to last until next Friday.

Lastly, Guy says that there is testing ongoing on ZA002 which includes tests on the electronic bay cooing system as well as tests on some computerized maintenance tasks.


Guy's 21st 787 Report

Guy Norris: ZA001 to start intermediate gauntlet tests today

UPDATE: Flightblogger is reporting that ZA001 is powered up and engines are running possibly signalling the start of gauntlet testing. Also Jon put up a few spectacular pics of the 787 from a different perspective. Jon's latest post.

Guy Norris posted on his blog early (very early) this morning that intermediate gauntlet should start later today. According to his report Boeing should have started some engine run tests at about 3 AM local time followed by a simulated Boeing B-1 standard profile first flight which all Boeing airplanes go through before they are delivered to customers. This should be followed by a modified B-1 test along with test of the GE-developed CCS (Common Core System).

There will be other systems tests during the day as well. If everything goes well, then intermediate gauntlet testing should conclude around June 5th. It's unknown how long final gauntlet would take but I'm opining that it would be about 3 to 4 days at the most but I'm not too sure. After the final gauntlet, Boeing would undertake Hot Fire tests of the engines and then low speed and high speed taxi tests with and RTO test thrown in there the day before first flight.

Let me wrap up by linking you to Randy's Jounrnal (Randy Tinseth's Blog at Boeing). He has a great view of the first engine tests that occurred last week.

Guy's 20th 787 Update
Randy's Journal

Flightblogger: ZA001 intermediate gauntlet to start today

UPDATE: Flightblogger is reporting that gauntlet testing along with the pre-gauntlet engine tests won't start until tomorrow. Today was "Shop Gauntlet Work" that took place.

Flightblogger is reporting that intermediate gauntlet testing on ZA001 may start as early as mid day today.

Boeing was to have some engine runs today followed by pre-gauntlet test meetings following those engine runs.

If things look good then Boeing should start the intermediate gauntlet tests today starting with a simulated first flight profile test with simulated failures of the aircraft systems. Boeing had already run through the intermediate gauntlet tests on the integrated test vehicle (ITV).

Lastly, Jon reports that ZA002 ran through its gear swing tests and ZA004 and ZA005 have their engines. That's Trent 1000s for ZA004 and GEnx for ZA005.

Also it appears that the LCF is not delivering the main fuselage section for ZA100 today.

Jon's May 28th Update

787 News - May 28,2009

Not too much to report except:

1) Boeing booked 5 orders from an unidentified customer for the 787. No word on which type (-8 or -9) though that will probably be revealed in a couple of weeks when Boeing releases its monthly order and deliviery numbers. Interestingly Boeing also booked a cancellation of 5 767s at the same time so I wonder if the cancellation has anything to do with the order for 5 airplanes? The only airlines that have the 767 on order (passenger version) are ANA, JAL and Lan. These carriers also have already placed orders for the 787 as well.

2) The LCF is on its way to Everett this morning from Charleston. It might be carrying the main fuselage section for ZA100 though we'll know a little later today.

No word on the start of intermediate gauntlet testing yet.

Flightblogger: Details on revised gauntlet testing on ZA001

Jon Ostrower revealed some of Boeing's revised gauntlet testing timetable and how it impacts the ZA001's path to first flight.

First off the maturity of the systems, given all the testing that these systems had undergone during the delays allowed Boeing to get these systems to a more mature flight ready condition than would have otherwise been possible.

Further Boeing is supposed to start intermediate gauntlet testing as either today or tomorrow and will run 7 days. Originally intermediate gauntlet wasn't going to be as long but they essentially have moved certain final gauntlet tasks to the left of the schedule and made them part of the intermediate gauntlet testing and thus shortening the time needed for final gauntlet testing.

Jon explains that Boeing is able to do this because they figured out what testing can be done concurrently and what test are absolutely necessary prior to first flight.

Lastly, Matt Cawby reported that Boeing undertook two HF radio checks as well as running the RAT twice to verify RPM and amperage as well as testing the high lift control system for the flaps and slats.

Flightblogger report

Matt Cawby's report

Flightblogger: Road to first flight getting shorter than planned

Evidence of Boeing's increasing confidence of the maturity of the 787 systems and architecture is leading the company to push up testing of the systems of the aircraft and even shorten the gauntlet testing that is needed before first flight according to Jon Ostrower.

Jon quoted Scott Francher, VP and general manager of the 787 program saying that intermediate gauntlet testing is due to start in about two weeks but due to the maturity of the systems this testing would last about 7 days instead of 8 days. Intermediate testing involves running the engines 24 hours a day for 7 straight days and subjecting the 787 to simulated failures and challenges and observing the reactions.

Also some of the final gauntlet testing will be now moved into intermediate testing further demonstrating the maturity of the 787 systems.

Much of this maturity came about becuase of extensive systems integration testing in the Boeing labs during the production delays of the last two years.

Recently Jojn reported that the engines were run at various times on Thursday at times to 80% of thrust. Flight control hyrdaulics systems tests were conducted as well as the VHF/HF radio tests. Today (Friday) higher power tests were to be conducted.

Jon's Road to 787 First Flight Update - May 22nd

787 Pre start activities on going

Guy Norris Updated his blog with Rolls Royce confirming that the engines are on. Guy also said that Boeing is speeding up ground testing with hydraulic testing slated for tomorrow. Intermediate gauntlet testing should start very soon.

Guy's blog posting.

UPDATE: ENGINES ARE ON!!!!

UPDATE: Jon Ostrower is reporting that intermediate gauntlet will start sooner than anticipated by Boeing. Good news! Also power on for ZA003 will occur very soon. Boeing is saying that gauntlet testing will be in the next two weeks and ground testing is progressing very rapidly. Also development work on the 787-9 has begun. Boeing plans to have firm configuration by the end of the 4th quarter of this year. Still planning on 10/month 787 production by mid-2012. Boeing have implemented several blocks of improvments in the production aircraft. First block has improvements mainly in the wing. Certification for lightening strikes is on going.

Pre start activities for the first start of the Trent 1000s are taking place. A fire truck has been moved up and the engine cowlings have been closed and locked. These pre start tests should soon lead to first engine start soon.

Dreamliner engines on?

UPDATE: Jon confirms that the test's last night was not engine start but the steps to engine start prior to actual ignition and start of the engines. Simply put, Boeing wanted to verify that fuel is flowing to the engines and that there are no issues prior to actually turning on the engines. Jon called it the "Braxton Hicks" engine start. Pretty Funny! Actual engine start and run at idle speeds should take place later this afternoon. I hope to have a video of it later on.

According to Flightblogger, ZA001 may have turned on it's Trent 1000 engines for the first time late last night (Thursday, May 20) and have them running at the idle setting but a comment left on Jon's post said it hadn't happened and that it was just spinning the engines and adding fuel. I'm still trying to find out what is happening.

Guy Norris also said that ZA002 is being prepared to go through factory gauntlet around this weekend and allow the aircraft ot be cleared for further gauntlet testing as well as fuel pad tests and roll out to the flight line.

Guy also reported that simulations are on going in the ITV (Integrated Test Vehicle) including simulations of the intermediate gauntlet tests that will take place shortly. Crews are also undertaking practice for ZA005 and ZA006 test flight in the ITV as well as testing the connection to the telemetry system that will download test data from the 787 test flight fleet to be processed and analyzed by the 787 flight test engineers.

Jon's Engine Report
Guy's 787 Update