Aircraft Industry: Incorrect shim work in the aft fuselage of the new Boeng 787 requires repair

At stake is the possibility of delamination in the Section 48 aft fuselage barrel of the new Boeing 787 twin-engine jet. In some areas, Boeing found gaps between the barrel, which is a single piece of composite material—carbon fiber reinforced plastic–and the fuselage’s internal composite support structure. Small gaps are normally filled with spacers called shims to ensure a tight fit. A lose fit promotes delamination over time.
 
Boeing says incorrect shim work in the aft fuselage of the 787 is limited to four locations, is “well understood” and will be repaired concurrently with other planned work.

“There is no need to conduct inspections or repairs on in-service airplanes immediately,” the company says in a statement. “There is no short-term safety concern.” Only All Nippon Airways is flying the 787.

The issue came to light in late January and concerns structures made at Boeing’s factory in North Charleston, S.C., a former Vought Aircraft facility. The company is not saying how many of the 50-plus aircraft built so far have experienced the issue, but all will be inspected.

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