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Explainer-What is the panel that blew off a Boeing plane in mid-air?

Published 01/07/2024, 12:11 PM
Updated 01/07/2024, 03:46 PM
© Reuters. FILE PHOTO: Passenger oxygen masks hang from the roof next to a missing window and a portion of a side wall of an Alaska Airlines Flight 1282, which had been bound for Ontario, California and suffered depressurization soon after departing, in Portland, Or

(Reuters) - A piece of fuselage tore off the left side of an Alaska Airlines-operated Boeing (NYSE:BA) 737 MAX 9 jet as it climbed following takeoff from Portland, Oregon, en route to Ontario, California, forcing pilots to turn back and land safely with all 171 passengers and six crew on board.

The panel that tore off is a plug put in place on some MAX 9s instead of an additional emergency exit, but not every plane is manufactured in such a way.


As Alaska Air (NYSE:ALK) Flight 1282 reached just over 16,000 feet on Friday, the panel tore off from the side of the jet, leaving a neat, refrigerator-sized, rectangular hole in the aircraft. The pilot immediately signaled that the plane would have to land.


The 737 MAX 9, currently Boeing's largest single-aisle plane, can seat up to 220 people. It includes an optional extra door to allow for the approved number of evacuation paths whenever carriers opt to install the maximum number of seats.

Planes that do not opt for additional seating can replace that door with a panel, or plug. Door plugs have been used to adapt aircraft and offer flexible layouts across the industry for years.


Of the 200-plus 737 MAX 9 planes Boeing has delivered, 171 have this panel in place of a door. In the United States, the carriers using that panel are United and Alaska. Other carriers that have grounded planes include Panama's Copa Airlines, Aeromexico and Turkish Airlines.


The fuselage for Boeing 737s is made by Kansas-based Spirit AeroSystems (NYSE:SPR), which separated from Boeing in 2005. Spirit is one of two suppliers that makes the plug doors on the MAX 9, but Boeing also has a key role in the plug installation process.


The installation is a two-tier process involving both manufacturing at Spirit's giant fuselage plant in Wichita, Kansas, and a Boeing factory outside Seattle, the sources said.

As part of the production process, Spirit builds fuselages for 737s and sends them by train with the special door assembly “semi-rigged,” according to a source familiar with production.

© Reuters. FILE PHOTO: Passenger oxygen masks hang from the roof next to a missing window and a portion of a side wall of an Alaska Airlines Flight 1282, which had been bound for Ontario, California and suffered depressurization soon after departing, in Portland, Oregon, U.S., January 5, 2024 in this picture obtained from social media. Instagram/@strawberrvy via REUTERS

At its Renton, Washington, plant, Boeing typically removes the pop-out door and uses the gap to load interiors. Then, the part is put back and the installation is completed. Finally, the hull is pressurized to 150% to make sure everything is working correctly.

The process means that finding out where any flaw was introduced during assembly may not be clear-cut, sources told Reuters.

Latest comments

First gay secretary of transportation and planes are literally randomly falling apart, just like everything else with the Biden admin. Recall the cross-dressing person Biden put in charge of the country's nuclear program was arrested for stealing women's clothing at the airport multiple times.
Call it what it is, it's a PATCH!   There is a deliberate opening there for an optional door the AA didn't want.  This is like driving 100 MPH on your donut spare tire.
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