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In his complaint, Sam Salehpour alleged that Boeing had taken shortcuts during the production of both its 777 and 787 aircraft, including misaligned fuselage sections and microscopic gaps that were not being properly filled during assembly. He claimed these issues could result in structural fatigue, potentially shortening the aircraft’s lifespan or even causing a catastrophic failure over time.
“I literally saw people jumping on the pieces of the airplane to get them to align," Sam Salehpour said during a press briefing in April 2024, adding, “That’s not how you build an airplane."
While Boeing strongly disputed the allegations, stating that the claims were “inaccurate" and affirming its confidence in the safety and durability of the 787, the FAA confirmed it had launched an investigation into the matter. The agency said Sam Salehpour’s report revealed ongoing concerns that the FAA had thought were already resolved.
According to ADS-B the aircraft had lined up runway 23 directly from the apron, without backtracking, leaving a takeoff distance available of 1900meters/6300 feet (By Simon Hradecky)