As authorities probe Boeing’s safety protocols as part of their investigation into what went wrong with a flight that blew a hole midair last week, the role of a major supplier is also coming into focus: Spirit AeroSystems.
Alaska
Jet accident probe expands to include Boeing supplier
Spirit builds the fuselage, or main compartments, of the Boeing’s 737 Max 9 jets at its Wichita factory before shipping them for finishing by Boeing. Spirit said its work on the fuselage includes completing the initial installation of the panel that broke off the Alaska Airlines flight, although it’s not clear whether the doors were reinstalled later. The company says it is responsible for manufacturing about 70 percent of each Boeing 737 aircraft before it is delivered by rail to Boeing’s factory in Washington.
At the Boeing factory, the plane’s wings, engines and internal components are installed before delivery to airlines. Investigators will seek to learn more about the manufacturing process with Spirit’s input, an NTSB spokesman said.
The Alaska jet was almost brand new, and four experts have said initial evidence suggests a problem that cropped up when it was being built.
So far, public attention has fallen primarily on Boeing, one of only two major airliner manufacturers globally. The company has struggled to repair its reputation after design flaws contributed to two deadly plane crashes several years ago. In remarks to employees Tuesday at Boeing’s 737 factory in Renton, Wash., chief executive David Calhoun said the company’s approach to Friday’s incident would involve “acknowledging our mistake.”
“We’re going to approach it with 100% and complete transparency every step of the way,” he said. The company distributed a transcript to the media and declined to comment on what Calhoun considered the company’s mistake. “We are going to work with the NTSB who is investigating the accident itself to find out what the cause is.”
In the wake of the Alaska Airlines incident, Spirit has said little publicly but started holding safety meetings Monday with teams across the company, spokesman Joe Buccino said. The meetings were focused on quality and following processes, he said.
“As a company, we remain focused on the quality of each aircraft structure that leaves our facilities,” Spirit said in a statement Wednesday.
Spirit is far less well known than Boeing, its biggest customer. It was spun out of Boeing in 2005 and now makes parts for several manufacturers, including Airbus, Boeing’s main competitor. But Boeing and Spirit remain closely intertwined and, along with engine companies, it ranks among the aircraft giant’s most important suppliers.
“They’re not making 737s without Spirit,” said Ronald J. Epstein, an analyst at Bank of America.
Spirit has struggled in the past year with a string of manufacturing problems that have delayed deliveries of the Boeing 737 Max, a series of midsize single-aisle passenger planes. The troubles have prompted a shareholder lawsuit alleging it was slow to disclose the issues.
The in-flight fuselage breach last week has put the Kansas company under scrutiny at a time when analysts say it was trying to rebound after a pair of crashes that previously grounded the Boeing 737 Max and the coronavirus pandemic shook the aviation industry.
Spirit was not implicated in the problems that caused the crashes of two 737 Max jets in 2018 and 2019, killing 346 people. But in January 2020, with the planes still ordered out of service by aviation authorities around the world, Spirit sent layoff notices to about 2,800 employees at its Wichita plant. They said at the time that the move was “a necessary step given the uncertainty related to both the timing for resuming 737 MAX production.”
As the coronavirus spread, the company took another major blow. It reduced its global workforce by 6,600 employees and cut pay for salaried workers, according to a November 2020 securities filing detailing its response to the pandemic.
“They were hit harder than any company in the business,” because of its heavy dependence on the 737, said aerospace analyst Richard Aboulafia. Grounding the Max, and the pandemic, he said, were “the makings of a huge crisis.”
The company struggled through, shifting to producing sorely needed ventilators for covid-19 patients at one point and taking $75 million in federal aid. Despite struggles to rebuild its workforce, analysts said it had appeared to be on a good path heading into 2024. In October, the company switched chief executives, hiring longtime Boeing executive Pat Shanahan and striking new financial terms with its biggest customer.
Boeing declined to comment on its relationship with Spirit or its role in the installation of the door plug. Spirit declined to comment on its relationship with Boeing.
In a sign of the Spirit’s importance to their home state, Rep. Ron Estes (R-Kan.), who sits on a key tax committee and leads an aerospace-focused caucus, and Sen. Jerry Moran (R-Kan.), who serves on one of the top transportation committees in the chamber, have long have been public advocates for Spirit.
Moran said Tuesday that he had been briefed by NTSB chair Jennifer Homendy on the Alaska incident and would continue to monitor the investigation.
“For the thousands of Kansans who work in aviation, their jobs depend on passengers feeling safe to fly,” Moran wrote on X.
The Max was cleared to fly again in late 2020. In recent years Boeing has been racing to fill orders for the plane from airlines around the world. But the discovery of manufacturing problems last year slowed deliveries.
Last April, Spirit notified Boeing that it had discovered problems with fittings on the plane’s vertical fin, the company disclosed in SEC filings. It said the issue was not an immediate safety threat, a finding that was confirmed by Boeing and the Federal Aviation Administration.
Spirit spent months fixing 737s located at its production facility in Wichita, at a cost of more than $30 million, according to an SEC filing.
By August, then-chief executive Tom Gentile declared in a filing that the costly repair work was “behind us,” adding “we look forward to executing on our customer commitments for the rest of the year.”
The same month, Boeing and Spirit disclosed that improperly drilled holes had been found on a rear bulkhead, causing more disruptions. In both cases the problems were uncovered before the planes carried passengers and the FAA said they did not pose an immediate safety risk.
In a complaint filed in December, lawyers for Spirit shareholders alleged that the company had known about the problems much earlier than when they were disclosed to investors. It also alleges the company ignored employees’ warnings about defects. The lawsuit cites an internal complaint filed by a former inspector at Spirit in early 2022 who alleges the company’s products “frequently contained defects” due to its “rushed production process.”
Gentile and his attorney did not respond to requests for comment.
“The company is schedule-driven, not quality-driven,” said the former employee, who worked at Spirit for more than a decade and spoke to The Post on the condition of anonymity because he still works in the aviation industry.
Company managers repeatedly discouraged the former employee and other inspectors from logging defects, the former employee said. “I’ve been saying for years that it was just a matter of time before something was going to happen.”
The suit also cites the account of another former employee who said auditors discovered in 2019 that torque wrenches were miscalibrated, an issue that could lead to parts being over- or under-tightened, threatening their structural integrity.
The shareholders’ complaint alleges that Spirit suffered repeated quality failures because it had not hired enough workers to meet demand and “prioritized production numbers and short-term financial outcomes.”
Spirit has not filed a response to the allegations in the lawsuit, which is still in its early stages. Buccino said the company disputes the allegations.
“Spirit strongly disagrees with the assertions made by plaintiffs in the amended complaint and intends to vigorously defend against the claims,” he said. “Spirit will not comment further as to the pending litigation.”
The aviation industry has struggled across the board with labor issues, seeing waves of job cuts at the beginning of the pandemic before scrambling to rehire workers as demand bounced back much quicker than many had expected. The result at a manufacturer like Spirit has been a loss of experienced employees who can help get new hires up to speed, analyst Aboulafia said, and which could contribute to quality problems.
In June, Spirit manufacturing employees, who had agreed to continue working under an old contract during the pandemic, briefly went on strike. The two sides soon reached a deal on wages, drug coverage and overtime, but company executives said the walkout caused another disruption to production.
Gentile was replaced as chief executive in October, and the company’s board turned to Shanahan to help chart the company’s path forward. He had worked at Boeing for three decades and served as deputy secretary of defense during the Trump administration. Shanahan quickly made a deal with Boeing to help stabilize the company’s finances and address manufacturing problems. Aboulafia said he was the right person to step into the role because “he can read reality to Boeing.”
A month into the job, Shanahan was clear about the challenges the company had faced. In a November earnings call, he used a military term to describe his approach to the job, saying he was at the company to “take charge and move out.”
“I recognize we have disappointed our stakeholders,” Shanahan said. “We want to restore confidence in the company.”
Alaska
Medley of Errors Causes Alaska Pilot’s Downfall
It was the last day of the hunting season. Tanks of fuel stashed at a remote Alaskan airstrip had to be retrieved. Time was short since a storm was approaching. A Cessna 206 landed on a gravel bar in the Porcupine River, and the pilot began loading 15-gallon fuel containers into the plane. To save time, she asked two hunters, who were waiting there for a different airplane, to empty two of the containers into her wing tanks. The whole operation lasted 12 minutes.
Seconds after the 206 became airborne, its engine sputtered. It banked steeply, and its right wingtip struck the surface of the river. The airplane cartwheeled before coming to rest, partially submerged. The powerful current and icy water of the river prevented the two hunters from getting to it. By the time a raft had been brought from the nearest base, 60 miles away, an hour and a half had passed. The pilot, 28, was dead.
Accident investigators minutely examined the 206’s engine and found nothing wrong with it. What was wrong was that there was water—in some places more water than avgas—in the fuel system, including parts that river water had not been able to enter.
A pilot who later inspected one of the smaller fuel containers found about a cupful of water in 8 gallons of fuel. Since the plane had arrived without any trouble, it was pretty clear that the water in the fuel system had been added along with the fuel during the hasty stopover on the sandbar and caused the engine to lose power soon after it went to full throttle.
What looked like one cause, however, was really several.
The fuel cache, which had been set up two months earlier, consisted of 55-gallon metal drums from which fuel was pumped into 15-gallon plastic containers that were easier for the pilot to handle. Fuel would be transferred from those containers into the airplane’s wing tanks by a battery-operated pump.
When the cache was originally established, the pump had a filter to trap debris. In addition, a Mr. Funnel was provided. It contained both a screening filter and hydrophobic membrane that allowed fuel to pass through but not water.
During the course of the hunting season, the pump’s filter became clogged and was removed. It was not replaced, even though the fact that it had gotten clogged seems to suggest that a filter was needed. The water-excluding funnel also was “lost”—whatever that means on an unfrequented sandbar—and it too was not replaced. Thus, nothing remained to ensure that fuel pumped into planes would be clean and free of water.
In principle, a final line of defense existed in the form of the airplane’s fuel drains. In this 1975 206 those were four in number (later Cessnas, whose integral fuel tanks can hide water behind ribs, have as many as 13). Two were, as you would expect, on the undersides of the wings at the inboard ends of the tanks. One was on the fuel strainer, or “gascolator,” at the firewall. The fourth drained a small collector tank located in the bottom of the fuselage.
The accident pilot, and other pilots who worked for the same flying service, were aware of the lack of filtration at the remote site and had “numerous conversations” about the danger of water contamination in fuel and the need to check the sumps after refueling. The 206 was equipped, however, with a belly pod that covered the fuselage sump drain, so that it might be necessary to shift or remove cargo in order to get at the drain. The accident pilot had repeatedly complained about the difficulty of draining the fuselage sump, and she was said to habitually skip that step despite “talks at great length” urging her not to.
Since the fuel pickup in each wing tank is located slightly above the bottom of the tank, small amounts of water could be taken from the quick-drains without any of that water having found its way to the fuselage tank. But if sufficient water got into a wing tank, some of it could run down into the fuselage tank, water being heavier than fuel. The fact that the engine ran for some time before stumbling suggests, however, that the fatal water came from the wings, not the fuselage tank.
According to the pilot’s colleagues, it was “company policy” that only the pilots themselves do the refueling at remote sites and not delegate it to anyone else. The hunters who pumped fuel into the 206 for the pilot recalled that she did not check the sumps before taking off and that there was no mention of the possibility of water in the fuel.
So, one by one, the conditions for the accident had been put into place. The mere fact that there had been “numerous conversations” about the danger of fuel contamination suggests that the company’s pilots knew that a potentially serious problem existed. The clogged fuel filter had not been replaced. The fuel storage tanks, even if they were impervious to rain, were likely to accumulate water from repeated cycles of condensation, and yet the water-filtering funnel was gone too. Why a replacement was not obtained is unclear. Amazon offers Mr. Funnel filters for around $40, delivered tomorrow (or, in the bush, maybe a few days later).
The National Transportation Safety Board blamed the accident on the pilot’s “inadequate preflight inspection,” with the company’s failure to replace the fuel filters a contributing circumstance.
The NTSB’s report omitted mention of a third factor.
The accident occurred on a meander in the river. The sandbar from which the 206 took off was oriented directly toward a broad gravel bank on the opposite shore. The immediate cause of the crash seems to have been the pilot’s decision to turn back, which led to the right wingtip hitting the water. If she had continued straight ahead, she might have made the far shore or at least ditched under control in the river. She might have lost the airplane in the process but saved her life.
A retired fighter pilot, who at one point during his career in the Air Force had the job of test-flying F-100s after they emerged from maintenance, told me that he wouldn’t hesitate to punch out of an airplane that failed of its own accord but would be very reluctant to abandon one whose problems he himself had caused.
In her haste, the pilot had not checked for water in the fuel, even though it had been a topic of much discussion. When the engine stumbled, she probably guessed the reason instantly. She switched on the fuel pump in hope that the engine would come back to life. Trying to save the airplane, she banked back toward the runway. But then…
This column first appeared in the December Issue 965 of the FLYING print edition.
Alaska
Kipnuk man receives longest sentence in Alaska’s history for sexual assault, abuse
ANCHORAGE, Alaska (KTUU) – A Kipnuk man was sentenced Tuesday to a composite sentence of 263 years to serve for 17 counts of sexual assault and sexual abuse of six children between 2006 and 2013. The court ordered that Paul was not eligible for discretionary parole.
According to the Alaska Department of Law, this sentence appears to be the longest sentence handed down for sexual assault and sexual abuse in the history of the State of Alaska.
The man is 37-year-old David Paul. He was convicted of 28 counts following a three-week jury trial held in Bethel in August. At sentencing, the convictions merged into 17 counts. Those included five counts of first-degree sexual abuse of a minor, six counts of second-degree sexual abuse of a minor, four counts of first-degree sexual assault and two counts of second-degree sexual assault.
In May 2021, one of the victims came forward as an adult to report Paul’s prior abuse committed against them. That victim also reported observing Paul sexually abusing a separate victim. During a several-month-long investigation, additional victims were identified and interviewed. These additional victims disclosed that Paul also sexually abused them when they were children.
Paul was arrested in October 2021.
During the trial, the jury heard emotional testimony from all six victims, who explained that they initially did not report the abuse as children because they were scared and did not think anyone would believe them.
Several of the victims gave impact statements at sentencing. They told the court about the lifelong impact of Paul’s crimes on them. Each expressed that Paul stole their childhood.
In the press statement from the Alaska Department of Law, one victim told the court that they had spent years blaming themself.
“I have spent years thinking it was my fault for not protecting my brother. I blamed myself for not knowing how to tell my mom at such a young age. I did not ask for this. Today I no longer blame myself, because what happened in the dark has come to the light,” the victim stated.
Assistant Attorney General Bailey Woolfstead emphasized the number of victims, the length and continued nature of the sexual assaults and abuse, and Paul’s manipulative and predatory behavior. She argued that his actions required the court to permanently remove Paul from the community to ensure that he never harmed another child.
Bethel Superior Court Judge William Montgomery stated that Paul constituted a “worst offender” under the law.
“The amount of damage that has been inflicted is unspeakable … I see no potential for rehabilitation for Mr. Paul. If Mr. Paul is out and about in the community he poses among the most severe threats to the community in the YK Delta, his behavior and criminal history has demonstrated such,” Montgomery said.
In handing down the sentence, Judge Montgomery stated his intent was to ensure Paul is never released from prison.
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Alaska
In Alaska Murder, Arresting the Boyfriend Was a Big Mistake
Alaska didn’t solve who killed 23-year-old Eunice Whitman, but its justice system did manage to lock up the wrong man for seven years, ProPublica reports, in a gripping investigation of two eerily similar murders that police have not linked. Whitman of Bethel, Alaska, was found in May 2015 on tundra at the end of a heavily-trafficked boardwalk: stabbed in the throat and chest, clothes removed and placed nearby. Police quickly arrested her boyfriend, Justine Paul, telling the public her blood was on his clothes. A grand jury indicted him 11 days later. The case then stalled for years as the supposed key evidence quietly crumbled: state lab testing showed the blood on Paul’s clothes matched him. Prosecutors ultimately dropped the charges in 2022. By then, Paul had spent seven years in jail awaiting trial.
His defense attorney, former prosecutor Marcy McDannel, came to believe police had focused on the wrong man while overlooking others. Male DNA on Whitman’s body did not match Paul, the four men who found her, or a registered sex offender seen in the area. A defense expert later identified at least a dozen people who, he argued, should have ranked as higher-priority suspects than Paul based on their proximity or past contact with Whitman. Among them: a man with a history of violence on the same boardwalk; an ex-boyfriend she named in a restraining order; and a man who had Whitman’s phone and a bandaged hand a week after her death. None were charged; two are now dead.
McDannel kept digging after Paul’s release and zeroed in on another possibility: convicted killer Samuel Atchak. Nine months before Whitman’s murder, 19-year-old Roxanne Smart was found in the nearby village of Chevak, also partially nude on the tundra, stabbed in the throat and torso, her clothing arranged close by. Atchak confessed in that case, saying he surprised Smart from behind before making her blackout, and is serving 115 years. In a 2022 prison interview, he coolly analyzed Whitman’s killing, theorizing about the attacker’s motive and method (surprise from behind with a “chokehold.”) He also recalled being in Bethel on the weekend of the killing, on a flight stopover.
State troopers later told McDannel that travel and medical records ruled Atchak out in Whitman’s case but did not share the underlying documents; Atchak has declined new interviews. Public pressure resurfaced in January, when an advocate for missing and murdered Indigenous people posted about Whitman online, prompting calls to police. In March, Alaska’s Missing and Murdered Indigenous Persons unit took over the case and says it is starting from scratch. However, Whitman’s family says they still haven’t been re-interviewed—and still don’t know who killed her. While officials concede “unacceptable” delays in the case, citing heavy turnover among rural prosecutors, they maintain that everyone acted properly.
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