FAA directives set contrasting 787 and DA40 compliance paths

The 787 measure covers certain -8, -9 and -10 aircraft. The regulator estimates that the prescribed inspections and adhesion checks will require around 34 labour-hours and cost $2,890 for each aeroplane. It identifies the underlying hazard as possible ignition within a fuel tank, with an explosion risk if lightning strikes.

An affected operator’s immediate decision is how much maintenance resource to reserve for this defined scope. The FAA estimate provides a planning baseline, not evidence of each operator’s eventual labour use or expenditure. Recorded completion effort and cost would determine whether that initial allocation needs revising.

For DA40-family aircraft, flight manuals must be amended and first inspections completed by the earlier of 100 flying hours or 100 days. The measure covers an estimated 987 aircraft on the US register and also calls for revised procedures and corrective measures addressing possible faults in door latching.

Operators must monitor both elapsed time and aircraft use: a busier aeroplane may reach the hourly limit before the calendar limit. The scheduling trade-off is therefore specific—preserve planned flying while ensuring the required actions are completed before the controlling threshold. The safety consequence identified by the regulator is door separation causing structural damage and potentially loss of control.