Some other 787 tidbits

Trying to get some more infomration on a slow new day today.

ZA001 will be taking to the air today for another flutter test flight today.

Matt Cawby reported in a post that ZA102 (LN 9) has finished its side of body modifications that were done in the Everett flightline tent.

Matt Cawby's 787 Update - March 9

This aircraft will be moved in the next couple of days to building 40-24 to one of the 767 slant positions on the 767 final assembly line to finish reassembly activities. The aircraft that is there now, ZA005 (LN 5) will be moved out to the flightline. Speaking of which, Dreamliner 5 and Dreamliner 6 won't be making their first flights until the 2nd quarter so that mean we won't see the GEnx-1B airplanes up until April at the earliest. ZA530 (LN 10) will be moved into the flightline tent to begin its side of body modifications.

ZA002 has landed in Victorville for a few weeks of flight testing then it'll be back to Boeing Field.

Here's Boeing's press release:

News Release Issued: March 9, 2010 3:59 PM EST

Boeing 787 Begins First Flight-Test Operations Outside of Washington

VICTORVILLE, Calif., March 9 /PRNewswire-FirstCall/ -- The second Boeing (NYSE: BA) 787 Dreamliner, ZA002, landed at 10:53 a.m. local time today in Victorville, Calif. This marks the beginning of the first flight-test operations outside of Washington state for the program.

The airplane will be stationed at Victorville for approximately three weeks. The crew will conduct ground effects testing among other activities.

During ground effects testing, the pilots fly the airplane very close to the runway to gather data regarding the aerodynamic effects and performance of the airplane during the takeoff and landing phases of flight. Quantifying this performance is part of the certification requirements for all new airplanes.

"Victorville's airfield is the former George Air Force Base," said Randy Neville, chief pilot for ZA002. "There is ample ramp space for parking and plenty of on-site facilities. There is a long runway and plenty of level, clear land along the approach to the runway. We can operate there without disrupting air traffic control or other commercial aircraft."

A crew of more than 150 employees will be stationed at Victorville while the airplane is there.These include the flight test engineers and support personnel required to prepare the airplane for each day's flights and to monitor performance and test equipment.

"Our confidence in the reliability of this airplane grows day by day," said Scott Fancher, vice president and general manager of the 787 program. "Taking the airplane out of state for the first time is a big step, but one we're ready for."

787 Round Up - January 6, 2010

Boeing Photo

Now that we're out of the Holiday's here's some news from around the 787 program.

First off I'm hearing that ZA004 should be out of building 40-24 very soon, perhaps even by tonight. ZA003 is still in the paint hangar which may indicate that ZA004 might fly before ZA003.

ZA001 continues to make almost daily flights and has, to date, racked up over 24 flight hours. ZA001 is flying to get Type Inspection Authorization ahead of certification testing that would be planned to start around mid February. The airworthiness test flights that are currently taking place are to ensure that all the systems perform as advertised as well as to make sure there aren't any flutter issues with the aircraft.

ZA002, which has not flown since Dec. 22, 2009, is undergoing post-flight checks as well as re-calibration and testing of several systems including the Common Core System according to Guy Norris of Aviation Week. There is still no word on when ZA002 will resume flying.

Guy Norris' 787 Test Flight Update

Now that Boeing has gotten the 787 flying, some attention will be turned to 787 production. Flightblogger has put up an article about the side of body modifications for the production 787s going forward. Currently the airplanes are assembled without the mods put in. Starting with airplane 16 (LN 16), which should be in Everett next month, the mods will be partially done at Boeing Charleston on Section 11 (center wing box) and at Everett on Section 12 (wing boxes) prior to the wing body join. This will continue through aircraft 49 (LN 49) and then with aircraft 50 there will be an incorporated redesign of the area that shown the lack of structural strength thus eliminating the need of the modifications that will be present in the first 49 787s.

Flightblogger: Boeing to incorporate Side of Body Mods into Production 787s

Flightblogger also published an interesting blog post comparing the takeoff noise footprint of the 787 vs the 777. Quite interesting and I do think the 787 does have a lower noise footprint vs the 77 but that should be expected. The 777 has a larger diameter engines vs the 787 but the 787 also has other noise reduction designs incorporated into the aircraft.

Flightblogger compares the sounds of 787 vs 777 at Takeoff

One none 787 note. The other airplane that Boeing is going to start test flying is the 747-8. The first one RC501 is still out on the Boeing flightline, presumably undergoing gauntlet testing. Last month I got word that first flight of this airplane is supposed to be on January 14th. While sources have recently told me that it's still the 14th they've also said that it's likely to slip, possibly to the 21st of January. Stay tuned for that one!

Breaking: Boeing clears 787 side of body issue; completes final gauntlet. 787 cleared for flight

Boeing Image

UPDATE: Boeing Says the window for Dreamliner 1's first flight open on Dec. 15th at 10AM

Just out on the newswires, Boeing Press Release:

Boeing 787 Dreamliner Program Completes Static Test Analysis, Gauntlet Tests

EVERETT, Wash., Dec. 10 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today completed the review and analysis of the static test that was conducted Nov. 30 to validate the side-of-body modification made to the 787 Dreamliner.

"I am happy to report that the program has validated the airplane structure for the 787 Dreamliner," said Scott Fancher, vice president and general manager of the 787 program.

Fancher also reported that the 787 team has completed final gauntlet testing on the first airplane. Testing lasted for just two days because only improvements made earlier this year during previous testing had to be examined. "We are very pleased with the results of this final functional testing. With the successful completion of static testing and this functional testing, our focus now moves to first flight."

During the test on the 787 Dreamliner static test airframe, the wing and trailing edges of the airframe were subjected to their limit load -- the highest loads expected to be seen in service. The limit-load test was required to clear the airplane for first flight. Boeing's test strategy is to conduct all limit-load tests and analyze data before conducting the ultimate load series, which is required for certification and will be conducted next year.

Boeing announced June 23 that it was necessary to reinforce an area of structure at the side-of-body section of the 787. The modification entails installing new fittings at 34 stringer locations within the joint where the wing attaches to the fuselage. The 787 team has completed modifications on the first three flight-test airplanes and the full-scale static test airplane.

First flight of the 787 Dreamliner is expected to occur after final flight readiness reviews, receipt of documentation from the U.S. Federal Aviation Administration and taxi testing. Both taxi testing and first flight are subject to weather conditions.

"We are pleased with the pace of progress in preparing to enter our flight test program," said Fancher.

Boeing still has to get final FAA clearance but I suspect that they would start taxi tests as early as Friday (tomorrow). Now the weather will be the determinant of when the 787 will finally leave the ground after almost two and a half years. What is surprising is that a first flight date has not been announced in the press release.

Flightblogger just put up a post, he expects taxi tests and final flight readiness review to take place on Saturday. Also the first three 787s (Dreamliners 1, 2 and 3) are done with the side of body modifications:

Flighblogger post

Another blog post, this time from Randy Tinseth of Boeing:

Randy's Blog

Guy Norris added his $5 to the news pot tonight. He adds that ZA003 is going through antnna and communications systems tests and is getting ready to join the test flight fleet. Read his blog:

Guy Norris: 787 Countdown to first flight (resumed) Part 5

Plethora of updates

As we get closer to first flight, bloggers and journalist are sending out all sorts of updates so let's summarize.

Basically the gist of the news coming out is that Boeing has started (and confirmed) final gauntlet for the 787. The reason for another gauntlet is during the last six months while Boeing dealt with the side of body issue, engineers made further refinements on many of the 787's systems. The final (shorter) gauntlet is to verify the modifications work and to verify the integrity of the entire 787 system integration.

Sources have told me that they still plan to finish gauntlet testing tomorrow. Now according to Guy Norris, Boeing has switch the order of the gauntlet blocks with testing the failure modes first and will test the B1 flight profile tomorrow.

The weather looks to play a major role on when the 787 takes off but before that Boeing still has to finish the final gauntlet, carry out taxi tests and more importantly give clearance for the 787 side of body issue. Boeing said it would take ten days to get the results so I suspect tomorrow and Friday are going to be big news days as that information should come out at that point.

I think Boeing will set a first flight date either tomorrow or Friday if the side of body is cleared and I think it'll occur on Tuesday, Dec. 15th weather permitting.

Until further news here are some of today's news links:

Randy's Journal

Flightblogger

Yet another Flightblogger

Guy Norris

Matt Cawby (has a great video of ZA001 performing some gauntlet testing)

Dec. 15th first flight date reaffirmed...so far

Sources told me that Boeing is still tracking for a first flight on Dec. 15th and that testing is proceeding extremely well. This information is further reinforced by Flightblogger's post earlier this evening.

In his blog, Flightblogger says that Dreamliner 1 is expected to begin a 2 to 3 day final gauntlet starting as early as tomorrow and concluding around Wednesday or Thursday. During this testing Boeing will test the 92 systems on board the aircraft as put them through a simulated B1 first flight. They will also put the aircraft systems through simulated failures and observe how the systems react.

After the gauntlet test are completed and pending a favorable review of the static test data from ZY997 (static test air frame), Boeing will proceed into low/high speed taxi test as well as reject take off test (hopefully to take place the day before first flight). Of course first flight is again predicated up on successful review of the static data, the completion of the gauntlet and taxi tests and favorable weather in the Seattle area.

Flightblogger : ZA001 proceeds towards final gauntlet

Update: Matt Cawby has blogged that it looks like taxi tests will occur late this week into the weekend:

Matt Cawby's Dec. 7th Blog Post

787 passes static wing load test

Future of Flight Picture

This evening several sources reported that the 787 static test air frame had passed the static wing load tests. This was later confirmed this evening in a Boeing press release which is below:

Boeing Completes 787 Dreamliner Static Test

EVERETT, Wash., Nov. 30 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today completed the static test necessary to validate the side-of-body modification made to the 787 Dreamliner. The company expects a full analysis of the test results to be concluded in approximately 10 days. A successful test result is needed to clear the airplane for its planned first flight next month.

During today's test on the 787 Dreamliner static test airframe, the wing and trailing edges of the airframe were subjected to its limit load -- the highest loads expected to be seen in service. The load is about the same as 2.5 times the force of gravity for the wing.

Boeing announced on June 23 that it was necessary to reinforce an area of structure at the side-of-body section of the 787. The modification entails installing new fittings at 34 stringer locations within the joint where the wing is attached to the fuselage. The modifications were completed on the first two flight-test airplanes and the full-scale static test airplane earlier this month.

"Today's test was an important milestone for the program. We will confirm the test results after the completion of our detailed analysis," said Scott Fancher, vice president and general manager of the 787 program.

Boeing engineers still needs to finish detailed analysis of the test data but it's looking very good. ZA001 and ZA002 are both back out on the flightline and it's expected that ZA002 will perform additional taxi tests this week. The detailed analysis should take about 10 days to complete but I expect that during this time Boeing will carry out the additional and needed gauntlet testing as well as taxi tests on the 787 in advance of the 787 first flight.

Now according to Matt Cawby's blog, both 787 ZA001 and 747-8F RC501 will attempt their first flights (B1 flight) on December 22nd. While this date is expected for the 787 this is a surprise for the 747-8F and is an attempt to take advantage of maximum exposure on both these aircraft and to show that these programs are back on track.

Matt Cawby's Nov. 30th Blog Post

Earlier both the Seattle Times and Flightblogger reported that the 787 had passed the crucial wing load test to 100% of design loads (the ultimate or 150% design load test will come in 2010 and is not needed for first flight but needed for FAA certification). The passing of the design load limit test means that the side of body fix designed by Boeing engineers works according to their computer models.

Seattle Times

Flightblogger

Wing Load test started on static test 787

Matt Cawby reported on his blog today that Boeing has started a wing load test on ZY997, the 787 static test air frame. More on this when I get more information.

Matt Cawby's Nov. 27 blog post

787 still tracking for Dec. 22nd first flight

According to sources Boeing is still tracking to a first flight on December 22nd. Boeing hopes to start testing the fix on the static air frame after the Thanksgiving holidays (next week) and verify what their computer models are telling them.

Once that is complete then the way should be clear to restart pre-flight gauntlet tests followed by taxi tests and then first flight.

Additionally, the remainder of the test fleet as well as the production models completed thus far should go through the side of body modification in fairly rapid order.

I would expect that Boeing should have a good understanding if the side of body modifications work soon after they complete the tests. They will still have to review the test results with the FAA and get their approval prior to the continuation of the test program.

Flightblogger: 787 Fleet location

UPDATE (11/22/2009): ZA002 has been moved out to the Everett flightline and it seems that all the wing to body fairings have been reinstalled indicating that reassembly tasks maybe complete. See a picture of the Everett flight line by clicking here.

Flightblogger posted a great summary of where all the 787s are and the status of each aircraft

ZA001/LN1 : In paint hangar undergoing reassembly and should move to building 40-24 (767 line) this weekend to complete those reassembly tasks

ZA002/LN2 : Finish modifications and is in building 40-24 for reassembly tasks

ZA003/LN3 : In building 40-24 under going side of body modifications

ZA004/LN4 : At the ATS Hanger under going side of body modifications

ZA005/LN5 : On the Everett flightline awaiting it's turn for side of body modification

ZA006/LN6 : On the Everett flightline awaiting it's turn for side of body modification

ZA100/LN7 : On the Everett flightline awaiting it's turn for side of body modification

ZA101/LN8 : On the Everett flightline awaiting it's turn for side of body modification

ZA102/LN9 : At the ATS Hangar awaiting it's turn for side of body modification

ZA103/LN10 : In building 40-26 undergoing final assembly

ZA104/LN11 : In building 40-26 undergoing final assembly

ZA105/LN12 : In building 40-26 undergoing final assembly

ZA115/LN13 : In building 40-26 undergoing final assembly

ZA116/LN14 : Parts are arriving (horizontal stab and wings in da house)

Flightblogger : Getting Oriented

Boeing confirms completion of mods on static air frame and Dreamliner 2

Both Photos Courtesy of Boeing

This out from Boeing early (very) this morning:

Boeing Completes Side-of-Body Installations on Two More 787
Dreamliners

EVERETT, Wash., Nov. 16 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) has completed installing reinforcements within the side-of-body section of two more 787 Dreamliners.

Over the weekend, employees at Boeing's facility in Everett, Wash., finished reinforcing the full-scale static test airframe and the second Dreamliner designated for flight test. Installations were completed Nov. 11 on the first flight-test airplane.

The modification entails installing new fittings at 34 stringer locations within the joint where the wing is attached to the fuselage.

"Our focus now is on completing the static test later this month, which will validate the modification," said Scott Fancher, vice president and general manager of the 787 program. "Concurrently we are restoring the airplanes and completing the functional tests required to fly by the end of the year."

The static test airframe is being refitted with strain gauges and instrumentation required for testing. Access doors, systems, seals and fasteners removed from airplane No. 2 to provide access are being restored in preparation for continued testing on the airplane. The first 787 also is being restored.

Fancher said the program is on track to fly the 787 by the end of the year.

"We are building momentum with each milestone we achieve," Fancher said. "This team is focused on its goals and bringing us ever closer to first flight."

I'm assuming that Dreamliner 2 will finish up reassembly activities inside 40-24. Additionally, Matt Cawby is reporting that the fatigue test air frame and Dreamliner 2 (ZA002, LN2) will swap places with Dreamliner 2 going into building 40-24 and the fatigue test air frame taking its place on the flightline prior to undergoing modifications for the side of body join.

Matt Cawby's 787 Update

787s on the move

According to Matt Cawby's blog, Dreamliner 2 (ZA002, LN2) has apparently completed it's side of body modifications and will be moved out of the temporary hangar on the Everett flightline.

In it's place Dreamliner 4 (ZA004, LN4) will be moved from the ATS hangar where it currently resides into the temporary hangar on the flightline for the modification work.. Dreamliner 1 (ZA001, LN 1) conducted VHF and HF radio checks but no word on when it will be pulled out of the paint hangar.

Since Boeing indicated that the modifications on ZA002 and ZY997 (static test) were to be completed within days, it does stand to reason that Boeing should be able to conduct the wing stress test on ZY997 within the next few weeks since I do believe the mods should be done on that aircraft too.

With Dreamliner 2 moving out onto to the flightline, Boeing will have the following 787s outside:
Dreamliner 2, Dreamliner 6, Dreamliner 7 and Dreamliner 8.

At last report Dreamliner 3 and Dreamliner 4 are at the ATS hangar and Dreamliner 5 is in building 40-24 (767 final assembly line). ZY998 (fatigue test) I believe is also in 40-24.

Matt Cawby's Blog

Boeing Announces that Side of Body Fix Complete on 1st 787

This just out of Boeing confirming what Flightblogger had reported just a couple of days ago, what is interesting is that ZY997 and ZA002 are not too far behind ZA001 which means a very steep learning curve for the fix to be installed. Boeing expects to verify the fix on the static test air frame later this month:

Photo of ZA001 in the Paint Hangar

Courtesy of Boeing

Side-of-Body Installations Complete on First Boeing 787 Dreamliner

EVERETT, Wash., Nov. 12 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) has completed installing reinforcements within the side-of-body section on the first 787 Dreamliner.

The modification entails installing new fittings at 34 stringer locations within the joint where the wing is attached to the fuselage. Installations were completed yesterday.
Boeing expects to complete the installations on the static test airframe and the second flight-test airplane in the coming days.

"Completing this work is a significant step toward first flight. We continue to be pleased with the progress of the team and remain confident the first flight of the 787 Dreamliner will occur before the end of the year," said Scott Fancher, vice president and general manager of the 787 program. "We will test the modification on the full-scale static test airframe later this month. As soon as we confirm the loads are being handled appropriately in the joint we will complete preflight activities on the
airplane."

Once the modification is complete on the static test airframe, it will be refitted with strain gauges and instrumentation required for testing. Access doors, systems, seals and fasteners removed from airplane No. 1 to provide access are being restored in preparation for continued testing on the airplane. Boeing continues to install fittings on the fatigue test airframe and the remaining flight-test airplanes. Other airplanes will be modified in the weeks ahead. Overall, the work on modifying airplanes is progressing well, Fancher said.

"We have a strong and capable team that has performed exceptionally well," Fancher said. "I'm very pleased with the team's dedication to meet our commitment to fly before the end of the year."

After airplane No. 1 is restored, the flight-test team will perform another set of gauntlet and taxi tests to ensure that all systems are ready for flight. Fancher noted that with the exception of a single high-speed taxi test, all remaining flight-test activities have been successfully completed on the first flight-test airplane.

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

Flightblogger: Boeing complete 787 detailed design of 787 fix

Flightblogger is reporting tonight that Boeing has completed the detail design and computer validation of the last few final parts that makes up the 787 side of body join reinforcement fix. These final parts are being fabricated and should be delivered soon to be installed on the static test air frame as well as the test flight aircraft that are currently undergoing the installation of the modification.

Flightblogger is indicating that given that Boeing has finished the detailed design and computer validation of the fix that they have overcome the load issues that were discovered last Spring. Flightblogger is saying the test results received thus far are looking good.

Flightblogger

In other 787 news, Fleetbuzzeditorial.com came out with some great pictures of the 787 final assembly line:

Fleetbuzzeditorial.com - ZA100 and ZA101 at Everett

Additionally, Fleetbuzzeditorial.com also put out an interesting piece about the 2nd assembly line for the 787. This line is going to be crucial for Boeing to meet it delivery obligations. Here the article addresses the issues of the 2nd line, the choice ahead for Boeing and the pitfalls facing Boeing.

Second Guessing 787 Second Line

Lastly, the LCF's continue to make regular runs between the 787 suppliers and Everett. The nose section , wings, main fuselage, horizontal and vertical stabilizers for airplane 12 (LN 12) are already in Everett and I do believe the rear fuselage section is also in there though I have no confirmation. There should have been a line move already or will happen soon so that LN 8 (2nd production aircraft) will be moved out of building 40-26 thus clearing the way for airplane 12 to start final assembly in the coming days. Thus far Boeing is looking to maintain a 1 airplane/month production rate and gradually ramping that up to 10/month by the end of 2012. LN 7, the first production 787 is already outdoor on the Boeing flightline sans the Roll Royce Trent 1000s:

ZA100

Flightblogger: some issues with side of body fix; Boeing: still tracking for first flight before year end

Some interesting developments today as Flightblogger put up a post this morning saying that though the side of body fix installation is going well thus far, but Boeing has issues with the fix on four of the eighteen stringers that need to have the fix installed (on each side of the aircraft) thus Boeing engineers have to redesign the fix for stringers 2 through 5 (they in the aft part of the wing

These stringers carry higher loads and are shorter compared to the other stringers. Apparently they weren't bearing enough load in simulations of the model thus needing a redesign. Flightblogger cited sources saying that this may put Boeing target of flying the 787 in 2009 in jeopardy. ZA001 was supposed to be out of the paint hangar by now according to Flightblogger, citing internal schedules. It has not yet made a reappearance on the Boeing Everett flightline.

Flightblogger also said that there has been significant progress in installing the fix on ZA002 and ZA004, so much so that these two aircraft are catching up to ZA001 and ZY997 (static test aircraft) in terms of completion.

Now the information that Flightblogger put out certainly got a lot of attention so much so that Boeing released the following statement from Scott Francher:

“The design of the side-of-body solution is on track. Installations of the fittings are proceeding well and we are pleased with the progress we are making on this important effort. We continue to be on track to fly the 787 by the end of the year.”

Now for a bit of analysis. Boeing did not address the specific issue of the need to redesign part of the side of body fix in their statement thus Flightblogger may be on to something. It would be very interesting what they have to say about it on Wednesday's earnings conference call where the big topic will continue to be the 787's long trek to first flight.

Flightblogger: Unanswered questions, cautious optimism

Boeing Statement on side of body fix

Boeing may start 787 re-test in early November

I've gotten word that Boeing test engineers are scheduled to be called back to the 787 static test rig. This could signal the testing of the side of body fix for the 787 to verify what Boeing's FEM is predicting. This is all conjecture at this point but a few weeks ago but Guy Norris reported that some of the flight test personnel are returning to work on ZA001 so it could be a good sign that the rework is going according to schedule.

My gut still tells me that first flight would be around last week of November to the first week of December.

787 - First Signs of Life?

Boeing: 787 Side of Body Fix underway

According to a blog posting by Randy Tinseth, Boeing has started the modifications to the side of body joint on ZY997 (static test air frame) and ZA001. He stated in the post that the other aircraft will start the modifications in the coming days.

My estimate is that the actual installation of the fix and closeouts of the 787 should take about 4 to 5 weeks. This should bring Boeing to the end of October in terms of the schedule. They would need a few weeks to test the fix on the static airframe and to analyze the data to make sure that full strength has been returned to the side of body.

787 "mod" underway

Lastly, Randy said that ZA001 is still located in the paint hangar while ZA002 is in the temporary structure on the flight line, ZA003 is in the factory, ZA004 is in the rented hangar at ATS, ZA005 is in the factory and ZA006 is next to ZA004 at ATS. ZY998 is out on the flightline presumably waiting for ZA002 to vacate the temporary structure so then it can receive it's mods.

Flightblogger is also reporting the same information and has a few more details.

Flightblogger 787 fix post

Flightblogger: Fix installation to start next week

Flightblogger is citing program sources as saying that Boeing will start installing the side of body reinforcement fix for ZY997 and ZA001 next week. The fix should take about a month to complete meaning that ZA001 should reemerge from the Boeing paint hangar around mid to late October. Modifying each aircraft takes about three months but that time includes the time needed to prep each aircraft to receive the modification and to remove the necessary panels and gain access to the areas where the work crews will install the parts. The actual parts installation should take about a month.

ZY997 is receiving the fix concurrently with ZA001 will undergo the same wing stress test that had revealed the problem in the first place. This is to ensure that the modifications work as modelled on Boeing's 787 FEM. Once the fix is validated then ZA001 should be cleared to undertake high speed taxi tests and rejected take off tests prior to first flight.

Lastly, Flightblogger says that Boeing is about to start final assembly on ZA104 (LN10) which is the 4th production 787. The 787 line in building 40-26 should pulse today clearing the way for ZA104 to be moved into position 1 on the assembly line. That means that ZA100 will be in position 4, ZA101 will be moved to position 3 and ZA102 will be moved to position 2.

Look for the other test flight 787s to also have the modification installed in them over the next couple of months. Timing is still yet unknown.

Flightblogger: 787 fix installation to start next week

Boeing Announces New 787 Schedule and Third-Quarter Charge

Boeing Press Release is below. There will be a conference call at 10AM today and will listen to it and try and get as much information as I can. The schedule jives with what Flightblogger had posted earlier.

CHICAGO, Aug. 27 /PRNewswire-FirstCall/ -- The Boeing Company (NYSE: BA) today announced that the first flight of the 787 Dreamliner is expected by the end of 2009 and first delivery is expected to occur in the fourth quarter of 2010.

The new schedule reflects the previously announced need to reinforce an area within the side-of-body section of the aircraft, along with the addition of several weeks of schedule margin to reduce flight test and certification risk. The company projects achieving a production rate of 10 airplanes per month in late 2013.

"This new schedule provides us the time needed to complete the remaining work necessary to put the 787's game-changing capability in the hands of our customers," said Boeing Chairman, President and Chief Executive Officer Jim McNerney. "The design details and implementation plan are nearly complete, and the team is preparing airplanes for modification and testing."

Based on the revised schedule and other assumption updates, the company has determined that the 787 program is not in a forward-loss position.

However, separate from the updated program profitability assessment, the company has concluded that the initial flight-test airplanes have no commercial market value beyond the development effort due to the inordinate amount of rework and unique and extensive modifications made to those aircraft. Therefore, costs previously
recorded for the first three flight-test airplanes will be reclassified from program inventory to research and development expense, resulting in an estimated non-cash charge of $2.5 billion pre-tax, or $2.21 per share, against third-quarter results. This charge will have no impact on the company's cash outlook going forward.

The 787 team working the side-of-body reinforcement has completed initial testing and is finalizing design details of new fittings that are expected to ensure full structural integrity of the joint. The static test procedure that uncovered the issue will be repeated and the results fully analyzed before first flight is conducted. Fatigue testing also will be performed on stringer components to validate the long-term durability of the modification.

The first 787 test airplane and static test unit have been prepared for the new fittings. Installation is expected to begin within the next few weeks.

Boeing will discuss this announcement during a webcast starting at 10:00 a.m. EDT today. That webcast is accessible through http://www.boeing.com/. The company will update its 2009 financial guidance in October when it reports third-quarter results.

End of August and the 787 summertime blues

Well we're quickly approaching the end of August, the end of summer and hopefully the end of a period that Boeing would like to forget. If it weren't for the side of body issue the 787 would be flying around Boeing Field now for about two months. Now we have to wait about another three month for that happen (if Flightblogger is correct) and another month from now to hear Boeing's revised schedule. Too much is now riding on this for them to get it wrong. So with that in mind let's try and look ahead to what's yet to come.

As some of you may know, Boeing big wigs flew into Everett last week from Chicago and I believe the big topic of conversation was the 787. But I am hearing that Scott Carson might be retiring at the end of this year. Coincidence or not we'll see but right now it's just a rumor. I wonder if it's another coincidence that Boeing filed building permits today for the North Charleston site. Me thinks not! Boeing needs the second line to recover the lost ground in 787 production so the second line is inevitable (I said so a year ago) and I think Boeing will add additional autoclave capabilities to the 2nd line. The question will be where will the 2nd line go? At this point, if I'm a betting man it will be North Charleston but that will hinge on the vote by Boeing Charleston workers weather to decertify its union on Sept. 10th. If it is decertified then I think North Charleston is a shoo in despite what concessions Washington State and the IAM would give to Boeing. Boeing needs to have uninterrupted production if they are to catch up with deliveries. IAM going out on strike every 3 to 4 years will only get in the way of that.

Now articles are out that Air Berlin is considering cancelling it's order for 25 787-8s whether this is a bluff to wring out more concessions from Boeing is unclear though it sounds like Air Berlin is making an issue of the delays as a cornerstone of their arguments. That's a little surprising as they would be grateful for the delays as Air Berlin has a lot of capacity right now and they would probably need to add capacity in the future after the world economy recovers and air travel with it.

Now let's see what's happening on the tarmac at Everett. Well not too much there there is a big pup tent in the middle of the Boeing flight line where several of the 787 that will be in line for the fix will receive it. Out on the flight line there are 4 787s: LN2 (in ANA livery), ZY998 the fatigue air frame, LN6 and another test flight 787 in the Boeing 787 livery which I suspect may be LN 5. I think LN 4 is probably in 40-26 and LN 3 is still in 40-22 and LN 1 in the paint shop. That means that LN 7 and LN 8 probably have made or will make a line move soon to clear way to start final assembly on LN 9. The parts of this aircraft are in Everett.

Guy Norris also reported that tests are still going on on LN 2 on the Boeing flightline. He also has a great article on Boeing's moves in Charleston as well.

Guy's August 25 787 update
Guy's Boeing-Charleston Article
Air Berlin Mulls 787 Cancellation

Lastly, is Wall Street turning bullish on Boeing and specifically the 787? According to Scott Hamilton at Leeham & Co. a couple of Wall Street analyst now have a brighter outlook on the 787.

Scott's article on 787 forward loss.