One Year In....The 787 year in review.

For the last 12 months I've been giving a monthly update on the 787 flight test progress with the exception of last month. With the one year anniversary of ZA001's first flight and the suspension of 787 flight activities, it seems an appropriate time to review the 787 program and try and take a look ahead to see what awaits the 787. It has been a year of triumphs and heartache within the program and the current forecast for the program is, at best, overcast.

787 - December 15, 2009 to December 14, 2010

December 15, 2009 was a day that Boeing hoped that see the start of putting the troubles of the 787 program in the rear view mirror. It was a day that cloudy and rainy (typical Pacific Northwest weather). The first 787, ZA001, made an on time takeoff and flew for a little over 3 hours. ZA002 flew one week later in a flight that was shortened by issues with the main landing gear door and the nose gear. Nevertheless these initial flights started Boeing on the path of initial airworthiness flight trials. The 787 achieved IAT in mid January 2010 which allowed Boeing to conduct test with the other test flight airplanes as well as with engineers on board. This allowed for the expansion of the787 flight test envelope which would include stability and control testings, flutter testing and functionality and reliability testing of the airplane.

Boeing added airplanes to the test flight fleet with ZA004 flying in late February, 2010 and ZA003 flying in mid March 2010. The near term goal of the program was to achieve Type Inspection Authorization for the 787. This is the point that would formally kick off the certification program for the 787. This point of the program was expected to be achieved by mid to late February, 2010 but was not granted until April 20, 2010. This was a major indicator that the program may suffer delays to the delivery schedule yet again. During this period Boeing had successfully test the 787 wing to the ultimate load limit test on ZY997, the static test airframe. This was a major certification test point that Boeing needed to accomplish given the issues that Boeing had found almost a year earlier with the side of body join and the weakness that was discovered.

Boeing continued testing throughout the spring and summer of 2010. They seemingly hit a very good flight test pace during late May/early June only to see the number of flight and flight hours flown to drop off a month later and then recover later in the summer. Progress was made in September through the early part of November with significant flight hours being posted especially with the GEnx powered 787s that had finally joined the flight test program. However there were set back to flight testing (and production) due to the time needed to inspect the horizontal stabilizers on all 787s due to Alenia's workmanship issues. Boeing needed to spend precious time and resources to inspect and conduct any repairs on the aircraft that were built and/or flying. Still despite the Alenia debacle, Boeing was still on track to deliver the 787 by end of 2010 until an early August Trent 1000 engine test in Derby, UK took a bad turn and the engine had an uncontained failure of it intermediate pressure turbine.

This was a major setback for Rolls and Boeing as it threw the entire schedule into doubt. Indeed, the engine that failed was due to be installed on ZA102 (LN 9) which was to be used for flight tests of production standard aircraft. Boeing had to delay delivery to mid February because of the unavailability of an engine for ZA102 within the needed time frame to start flight tests on this aircraft.

Still Boeing said they were confident in Rolls Royce's hardware and software fixes to prevent a recurrence of the failure and Boeing continued with flight and ground testing of the 787 through early fall until Nov. 9th.

ZA002 was flying a long duration test flight with FAA personnel aboard testing the nitrogen generating system (part of the fuel inerting system) and was on final approach to an airport in Laredo Texas when a fire erupted in the lower electronics bay near the left wing. The fire was out after about 30 seconds but the power panel where the fire originated was destroyed and the aircraft had experienced power distribution problems while in the process of landing. An emergency was declared (apparently after landing) and the crew and test personnel evacuated the aircraft using the emergency slides.

The problems that lead to the fire in the P100 power distribution panel are now well known but now at this point, one year after the first 787 flew the 787 schedule is in shambles. The aviation world is waiting for Boeing's revised schedule. The 787 has had more than its fair share of problems and delays since it was launched in 2004 and there's nothing to say that there won't be any more issues when Boeing and the FAA resumes flight testing.

Boeing is still encountering supplier and production issues and probably will continue to see sporadic halts to part deliveries into Everett. Clearly there is still plenty of issues that need to be cleaned up so that Boeing can start deliveries of the 787 and ramp up production. However, the aviation world is now waking up to the fact in light of problems in various aircraft programs (A380, 787, A400M, F-35, and the A350) that the old model that aircraft manufacturers used to develop, design, test and produce high technology aircraft is out the door. Robert Wall of Aviation Week summed it nicely in a blog post a week ago: "Skeptics quip that Airbus is effectively fighting the last war, and that the only thing it is assuring is that it will invent a whole new series of missteps. If that turns out to be true, then perhaps it is time to put to bed the idea of accelerating development cycles on major products and just learn to live with the fact that the gestation period for a major civil aircraft program is eight years or longer."

Four Months In...787 Flight Testing Update

Four months after ZA001 embarked on its first flight the 787 test flight fleet continues to rack up flight test hours across four airplanes. Some of the milestones that were completed over the last month include:

• Completion of ground effects testing in Victorville, CA by ZA002
• Completion of flutter testing by ZA001
• Achieved 15% of total flight test hours
• ZA001 flies over 300 flight test hours
• ZA002 flies over 100 flight test hours
• ZA004 flies Wedge V5.5 service ready software
• Successful completion of the ultimate load test to 150% of maximum load on ZY997

One notable achievement that was supposed to be achieved during the past month was the issuance of the Type Inspection Authorization (TIA) by the FAA but as of today it still has not been issued. Word is that ZA002 needs to finish testing of the latest version of the flight control software before the FAA can issue the TIA. The issuance of the TIA may occur on April 16th though I am taking that date with a grain of salt. Still if it is issued tomorrow it does represent another 2 week slide in the test schedule thus eating up a total of 2 months of the schedule margin that Boeing allowed for itself. This may indicate that certification would not be given until early to mid December. I'm still waiting to hear from Boeing regarding the TIA.

As of April 14th, Boeing has flown 486 flight test hours spread across 164 test flight. The average flight has lasted about 2 hours and 58 minutes. The average flight utilization continues to decrease. In March it was 2.91 hours per flight and half way through April it is down to 2.65 hours per flight.

In order for Boeing to certify the 787 by early December (33 weeks), the 787s would have to fly over 2,600 flight hours which would equate to over 79 flight test hours per week. I speculate that the reason for the low number of flight test hours is the need to get the TIA from the FAA so that the real certification flight testing can commence. This seems to be the long pole in the tent at this point.

As far as ZA005 and ZA006, the GEnx powered aircraft maybe delayed even further though no reason has been given. ZA005 might be delayed to May 24th and ZA006 won't fly until June 21st.

Production is continuing with the 21st 787 entering final assembly. The 22nd 787 will start final assembly in about 10 days. Saj Ahmad of fleetbuzzeditorial.com has a great take on the the availability of early 787 delivery slots and their value in the market place. QANTAS and Virgin Blue are looking for early delivery slots with the former already having the aircraft on order and the later having converted to firm 777-300ER to options and possibly looking for early delivery slots for the 787. Read Saj's article here:

Fleetbuzzeditorial.com : Boeing 787 Slots Become Sudden Precious Commodities

Boeing declare success on ultimate load test

Boeing says that last weeks ultimate load test were success after thoroughly reviewing the data. This means that Boeing has cleared a major certification hurdle for the 787 and confirms that the side of body fix did its job. Here's Boeing press release on the test results:

News Release Issued: April 7, 2010 1:49 PM EDT

Boeing Confirms Success on 787 Wing, Fuselage Ultimate Load Test

EVERETT, Wash., April 7 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) announced today that all test requirements were successfully met during the 787 Dreamliner’s ultimate load wing and fuselage bending test. This follows a thorough analysis of the results from a test on the 787 static test airframe.

“Successfully completing this test is a critical step in the certification of the 787. This is further validation that the 787 performs as expected, even in the most extreme circumstances,” said Scott Fancher, vice president and general manager of the 787 program for Boeing Commercial Airplanes.

On March 28, loads were applied to the test unit to replicate 150 percent of the most extreme forces the airplane is ever expected to experience while in service. The wings were flexed upward by approximately 25 feet (7.6 meters) during the test and the fuselage was pressurized to 150 percent of its maximum normal operating condition.

In evaluating the success criteria for the test, Boeing specialists have been pouring over the thousands of data points collected during the test to ensure that all parts of the airplane performed as expected.

“The airframe performed as designed and retained the required structural integrity. These results continue to validate the design of the 787 as we move toward certification,” explained Fancher.

Video of the static test can be found at the 787 flight test Web site at www.boeing.com and www.newairplane.com.

Boeing confirms success of 787 Ultimate Load Test

Boeing Photo

Hours after conducting the ultimate load test, Boeing announced that the test has been completed successfully based on preliminary examination of the data. It will be a few more weeks of detailed analysis by Boeing structural engineers. The wings were deflected to 25 ft high during the test. Once the data is analyzed by Boeing it will be sent to the FAA as part of the certification program. This is a huge hurdle that Boeing overcame especially in light of the side of body issue that was revealed over 6 months ago. Here's Boeing's press release:

Boeing Completes Ultimate-Load Wing Test

EVERETT, Wash., March 28, 2010 – Boeing today completed the ultimate load wing up-bending test on the 787 Dreamliner static test unit. During the testing, loads were applied to the airframe to replicate 150 percent of the most extreme forces the airplane is ever expected to experience while in service. The wings were flexed upward by approximately 25 feet (7.6 meters) during the test.

Initial results of the ultimate load test are positive. More extensive analysis and review are required before the test can be deemed a success.

“The test program has been more robust than any conducted on a Boeing commercial jetliner,” said Scott Fancher, vice president and general manager of the 787 program, Boeing Commercial Airplanes. “It has taken countless hours of hard work by the Boeing team and our partners to work through the static test program. Everyone who has been involved in this effort over the past several years should be very proud of their contributions to ensuring the safety of the 787 Dreamliner.

“We are looking forward to the technical team’s report on the details of the test results,” said Fancher. It will take them several weeks to work through all of the data.

During each second of the more than two-hour test, thousands of data points were collected to monitor the performance of the wing. Key data points are monitored real-time during the test, but all of the data will be evaluated in the weeks ahead.

The next major milestone is the issuance of the Type Inspection Authorization (TIA) that will kick off the formal certification of the 787 by the FAA with their inspectors and engineers flying on board the 787 during the certification test flights. That is expected any day now, perhaps as early as tomorrow.

Guy Norris, Flightblogger and Saj Ahmad also posted info on the 787 ultimate load test. Here are the links for your reading pleasure:

Guy Norris: Wing ultimate load test complete on 787

Flightblogger: Confirmed: ZY997 completes 150% ultimate wing load test

Saj Ahmad: Boeing 787 Wing Test Milestone Completion

787 ultimate load test to be conducted today

Boeing Photo

UPDATE (6:21 PM on March 28th): Flightblogger just tweeted that the test has occured and that indications are that the wing had passed the 150% ultimate load test with no funnies. Good news!

Boeing has scheduled the ultimate load test for the 787 wing today, March 28th. the test was to occur between 10 AM and 12 noon Pacific Time. Since it is past that time there is still no word on if the test was conducted and the results (if any).

In order for the test to be undertaken today, Boeing cleared buildings 40-22 (747 assembly), 40-23 (static test) and the 40-24 buildings of all personnel except for the test engineers that are sequestered in a "bomb shelter" in building 40-23. This is in case the wing fails before it reaches the 150% load threshold. Boeing doesn't plan to break the wing above the 150% threshold.

I am still waiting to hear about results but until then here's a great article from Bloomberg about the 787 ultimate load test.

Bloomberg: Boeing plans critical test on Dreamliner today

787 News Round Up

The 787 program continues apace with the pending TIA for the 787. Production continues with a new milestone set to take place on Monday, March 29th. That day the parts for LN 20, which is the first weight optimized 787, will be loaded into the assembly tool at position 1 in building 40-26.

The aircraft, ZA175, is destined for Japan Airlines with GEnx engines. The line will move on March 28 with LN 16 coming out and going to the paint hangar. Also on that day Boeing will hopefully be conducting the extremely important ultimate load test on ZY 997. Currently, Boeing is conducting tests on the static air frame in a build up to the ultimate load tests this Sunday. Mike Mecham of Aviation Week has a great blog post describing the ultimate load test.

Mike Mecham : The final wing bend (hopefully)

In other news, LAN airlines confirmed news that was already known...that they will take some of the early 787s. In total they're moving up the delivery of 10 787s with LN 10 and LN 16 due to be delivered in about a year from now during the 2nd quarter of 2011. Here's LAN's press release:

LAN Will Be One of the First Airlines in the World to Receive the Boeing
787 Dreamliner

SANTIAGO, Chile, March 25 /PRNewswire-FirstCall/ -- LAN Airlines S.A. ("LAN" or "the Company") (NYSE: LFL; IPSA: LAN), one of the leading airlines in Latin America, and its subsidiaries today announced that the Company signed an agreement with Boeing to adjust the delivery of ten Boeing 787-8 Dreamliners to be incorporated into the Company's long haul fleet. This new delivery schedule anticipates by three years the arrival of this aircraft, previously scheduled for 2014 and now expected starting in the first semester of 2011.

In this way, LAN becomes the first airline in the western hemisphere to receive the Dreamliner, which is expected to revolutionize the airline industry, incorporating the most advanced technology. These ten aircraft are part of the original order for 26 Boeing 787s placed by LAN in 2007 and previously scheduled for delivery between 2014 and 2019. In addition, LAN has outstanding orders for six leased Dreamliners.

The Boeing 787-8 undertook its first flight in December 2009 and is expected to begin commercial operations in 2010. It has the capacity to seat approximately 250 passengers, providing a unique in-flight experience due to innovative technological advances featured inside the aircraft cabin. In addition, Dreamliners are fuel efficient and ecologically friendly, providing a significant reduction in emissions.

The Dreamliners will assist in the renewal and growth of the Company's long-haul fleet, allowing LAN Airlines and its subsidiaries to serve international destinations, improving connectivity between Latin America, Europe and the United States.

Mr. Enrique Cueto, LAN's Chief Executive Officer, stated, "The incorporation of the Boeing 787 ensures the Company's sustainable growth while preserving the environment and incorporating state-of-the-art technology to deliver the best travel experience for LAN's passengers. LAN looks forward to incorporating this new generation of aircraft in the first half of 2011."

"Partnering with LAN Airlines, one of the world's great air carriers, is an exciting way to introduce the 787 to the flying public. We look forward to seeing the Dreamliner fly with LAN's livery. The 787 Dreamliner represents one of those rare generational advancements in powered flight that will provide superior operating economics, compelling environmental performance and unique passenger comforts. LAN and its passengers will be among the early beneficiaries of these enhancements," said Marlin Dailey, Vice President Sales Boeing Commercial Airplanes.

Flightblogger says that LAN will be joining the likes of ANA, Air India, Continental, JAL, Qatar Airways, Ethiopian, China Southern and Royal Air Maroc as operators of the 787 by 2011. Read Jon's post:

LAN confirms early 787 arrival

Flightblogger: Ultimate Load Test to be conducted on March 28th

Boeing Photo

An important test for the 787, called the ultimate load test, will be conducted by Boeing on the static test air frame on March 28th. This test is important as it will validate Boeing's wing design to withstand 150% of the limit load that the wing will experience. This test is required by the FAA as part of the certification of the aircraft. Passing this test means that a huge hurdle in the design of the aircraft has been passed.

This test comes on the heels of the side of body fix that was needed on all the 787s to strengthen the join between the wing and the center wing box of the airplane. Without the fix, Boeing would have failed the ultimate load test. It had previously passed the limit load test though there was some delamination of the composite material.

The test will be conducted ZY997 which is the static test air frame.

Flightblogger article

787 Update - January 10, 2010

Yesterday another flight test 787 showed up on the Everett ramp being prepared for it's first flight. Sources tell me that this aircraft is ZA004 but a registration has not yet shown up on it's side.

ZA003 should show up very soon on the Everett ramp as well very soon to start it's preparations for first flight.

Both ZA003 and ZA004 are projected to have their first flights in the first week of February.

Additionally, Matt Cawby reported on his blog that the fatigue test air frame is very close to finishing its side of body modifications and should be moved to the fatigue test area around January 30th to start 3 years of fatigue testing. It will be moved out of the temporary hangar that is on the Boeing flight line.

Matt Cawby's January 9, 2010 Blog Update

Flightblogger got a great article up on the production challenges that the 787 still faces now that the aircraft has entered test flights. Thus far Boeing has completely assembled 1 complete 787s (LN 1 through LN 11) plus two test air frames (ZY997 and ZY998). Currently there are 4 aircraft undergoing final assembly (LN 12 through LN 15) and parts of LN 16 are just starting to arrive in Everett. Flightblogger is reporting that Boeing planes to start increasing production on the 787 round mid February.

Flightblogger: Dreamliner Production Challenges Lie Ahead

Finally through today, January 10, 2010, the 787 test fleet has accumulated over 45 and half hours test flight hours. Also today, Za001 flew the longest 787 test flight thus far at 5 hours and 48 minutes. You can track the 787 flight test hours by going to this spreadsheet here.

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

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.

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

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

Flightblogger: Where in the world are the 787s?

Flightblogger posted a great article today showing how close Boeing is to starting the installation of the side of body fix on several of the test flight 787s.

In his post, Flightblogger detailed the locations of the 6 test 787s plus the static and fatigue frames and the 3 production frames. Here's a synopsis of the locations of these airplanes:
ZY997 - building 40-23 - all prepped for installation of fix, awaiting parts installation
ZY998 - Boeing Everett flightline
ZA001 (LN1) - paint hangar 45-04 - all prepped for installation of fix, awaiting parts installation
ZA002 (LN2) - temporary hangar on Boeing flight- prepping for side of body fix
ZA003 (LN3) - building 40-24 (767 line)
ZA004 (LN4) - ATS hangar - prepping for side of body fix
ZA005 (LN5) - building 40-24 (767 line)
ZA006 (LN6) - stored on Boeing Everett flightline to be towed to ATS hangar to be prepped for side of body fix
ZA100 (LN7) - building 40-26 position 3
ZA101 (LN8) - building 40-26 position 2
ZA102 (LN9) - building 40-26 position 1

Additionally ZA104 (LN10) has some parts already in building 40-26. There should be line move occurring very soon which allow the reaming parts to be flown in and final assembly start on this aircraft.

Getting Oriented: Where's the 787 fleet? Part Two

Also some great stuff from Randy Tinseth at Boeing:

Mod Squad

Undercover Airplane