Boeing Keeps Temporary 787 Rivets on Test Flights

Jason Sandefur

Boeing Co. is reportedly proceeding with test flights on its 787 Dreamliner without replacing all the “temporary or improperly installed” fasteners on the test jet.
A shortage of fasteners plagued production of the Dreamliner from the start. Boeing announced an initial six-month delay and promptly replaced the head of its 787 program and deploying engineers into the field to help suppliers boost production. The test aircraft had to be delivered with temporary fasteners.
Months later came the news that Boeing was scrambling to replace other fasteners that had been improperly installed. That problem was traced to an engineering error made at the company’s facility in Everett, WA. The bolts in question were used inside the fuselage to fasten titanium structure to carbon-fiber-reinforced plastic composite.
Since then, Boeing machinists have been unable to replace incorrect fasteners in hard to reach places. Boeing said fasteners that don’t meet specifications are non-critical areas and will be replaced following completion of test flights.
A pressurization test revealed a small gap under the heads of thousands of fasteners inside the fuselage. The specification that mechanics consult for precise instructions made proper installation impossible.
Boeing is replacing uncoated nutplates on nearly four hundred 737s delivered after August 2007. The nutplates lack a cadmium coating that would help prevent corrosion on adjoining aluminum parts. Other widebody jets – 747s, 767s and 777s were also affected. �2009 FastenerNews.com