WICHITA, Kan. -- If you want to see 787 Dreamliners be fully assembled, you have to go to either Everett, Wash., or North Charleston, S.C. But if you want to see how the front section of the next-gen airplanes are made, you have to travel to Kansas.
For decades, Boeing had a large presence in Wichita, but in 2005 the company decided to spin out its facility here as a private company. And that's how Spirit Aerosystems was born. Now, Spirit is involved in the manufacturing process for a number of major aircraft, including the Dreamliner, Boeing's 737, 777, and 747, as well as some of Airbus' airplanes.
As part of CNET Road Trip 2014, I visited Spirit in Wichita to see how the Dreamliner's front section comes to life.
Above, you can see what is known as a "barrel," the very beginning of a front section. The barrel is comprised of several smaller sections known as mandrels. Once the mandrels assembled, a giant machine methodically winds thousands of pounds of composite "slit tape" around the barrel, gradually forming the shape of the forward section.
Click here for my full story on the production of 787 Dreamliner front sections.
Still being wrapped in composite material, the barrel is suspended between two sides of this giant blue tool. Once the wrapping is complete, the barrel will be placed in one of the world's largest autoclaves.
Most of Boeing's airplanes have traditionally been made with aluminum. But with the 787 Dreamliner, it began using composite materials. These are rolls of the composite tape that will be wrapped around a barrel.
When a barrel goes into the autoclave, it is black. When it comes out, it is this silver color. That makes it easy to tell if a Dreamliner barrel has been in the autoclave or not. When the barrel comes out, it's also entirely smooth, with nothing cut out.
Here, we see a Dreamliner front section canted to one side as it sits in the trim and drill position. The front section can be rotated on its central axis any way that's necessary to allow workers the easiest access.
A front section is suspended upside down as workers fasten various components to its structure to increase its strength. These components are generally aluminum or titanium and are only installed on the interior of the structure.
In the final assembly area, Spirit works on installing systems in as many as eight Dreamliner front sections at a time, while also having two stations where the Dreamliners are powered-up for the first time.
Even though this Dreamliner is still just a front section, it is powered up prior to shipping to Boeing. Many of the cockpit systems are tested as if the plane was complete. The aircraft doesn't know that it doesn't have wings or the rest of its body.
After everything has been done, it's time to send the Dreamliner front sections to Boeing. Here, two of them sit, ready to be loaded onto a Dreamlifter and then flown to Washington state or South Carolina.
A completed Dreamliner front section is seen being loaded onto the Dreamlifter, the special airplane Boeing built to fly the Dreamliner's major components to its factories in Washington state or South Carolina for final assembly.