Comment Unexplained: door plug manufactured for another AC (Score 1) 114
Not only is it unknown to the FAA who botched the remounting of the door plug and forgot the 4 bolts. It's not known, at least publicly, why that particular door plug is the one that was remounted.
Fact: The door plug that fell out from the sky bears the marking "LINE UNIT:8799" (source: press photo).
Fact: Tthe NTSB preliminary report states the accident aircraft has Fuselage Line 8789 (notice the one-digit discrepancy). And fuselage Line 8799 is that of a later aircraft delivered a month later.
Hence, the door that fell was manufactured with the intention of fitting it to an aircraft earlier in the assembly line (or is marked wrong).
We also know from a whistleblower that at one point, the door seal was found to be damaged. And no replacement door seal was immediately available. That creates an incentive to swap the door, solving the seal problem, which would perfectly fit the the above evidence.
It's common practice in manufacturing to “cannibalize” parts up in the assembly line to finish the unit that's next to be delivered. I know no reason why it would have been objectionable in the circumstance, subject to
- proper paperwork documenting the swap
- remounting the screws properly
- duly inspecting that.
But it looks like these three steps have have been skipped. And that should be a big deal.