Boeing 787 Cargo Doors Built Wrong? FAA Demands Inspections Now
Published Date: 8/20/2026
Proposed Rule
Summary
The FAA proposes to adopt a new airworthiness directive (AD) for certain The Boeing Company Model 787-8 airplanes. This proposed AD was prompted by a report that large forward cargo door (LFCD) split frames may have been manufactured with a material that did not conform to type design. This proposed AD would require an inspection of the LFCD split frames for affected batch numbers and applicable on- condition actions. The FAA is proposing this AD to address the unsafe condition on these products.
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
On-Condition Replacement Requirement
If the inspection finds affected LFCD split frames, the proposed AD would require replacing each affected LFCD split frame with a new LFCD split frame made of Ti-6Al-4V alloy. The replacement uses a kit that includes all 5 LFCD split frames and hardware; the document lists parts cost and labor for one kit (parts $104,100; labor 32 work-hours at $85/hour = $2,720; total $106,820 per kit).
Possible Manufacturer Warranty Coverage
The FAA notes that, according to the manufacturer, some or all of the costs of this proposed AD may be covered under warranty, which could reduce the cost impact on affected operators.
Mandatory LFCD Split-Frame Inspection
If you operate affected Boeing Model 787-8 airplanes, this proposed rule would require inspecting large forward cargo door (LFCD) split frames for affected batch numbers using Boeing Alert Requirements Bulletin B787-81205-SB530106-00 RB (Issue 001, dated February 4, 2026). The FAA estimates the inspection takes 2 work-hours (2 x $85 = $170) per airplane.
Small U.S. Fleet Affected
The FAA estimates this proposed AD would affect 4 airplanes of U.S. registry. The agency estimates the total cost for the required inspections on U.S. operators would be $680 (4 airplanes x $170 inspection per airplane).
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