OXYGEN SYSTEM FAILURE: In 2017, Barnett's team discovered that 25% of the emergency oxygen systems on 787 aircraft would fail to deploy oxygen to passengers in an emergency. He reported this to management, was stonewalled, and alerted the FAA directly. Boeing's own internal investigation confirmed malfunctioning oxygen masks.

DEFECTIVE PARTS INSTALLED: Barnett reported that workers did not follow procedures to track components, allowing defective parts from the non-conforming parts bin to be installed in aircraft. A 2017 FAA report confirmed that at least 53 "non-conforming" parts were missing and ordered Boeing to take remedial action.

METAL SHAVINGS NEAR FLIGHT CONTROLS: Barnett discovered clusters of metal shavings from titanium e-nut installation left near electrical systems for flight controls. He warned this could have "catastrophic" results if shavings penetrated wiring. Boeing transferred him rather than addressing the issue. The FAA issued a 2017 directive mandating removal.

DEBRIS IN AIRCRAFT: Barnett received complaints about tools, drawings, fasteners, and other debris left inside completed 787 aircraft. On one test flight, a ladder was found inside a horizontal stabilizer, a potential flight safety hazard.

PRODUCTION CULTURE: Barnett described Boeing South Carolina management as hiring mechanics whose previous experience was in fast food, saying the factory "smelled of French fries." He blamed a culture shift from the defense-based management motto: "we're in Charleston and we can do anything we want."

WHISTLEBLOWER RETALIATION: Barnett alleged he was denied a promotion, demoted in 2013, transferred to an undesirable department in 2015, and blocked from a position at NASA's Michoud Assembly Facility. He filed an AIR 21 whistleblower complaint with OSHA in 2017.

DEATH DURING DEPOSITION: Found dead of a gunshot wound on March 9, 2024, in a hotel parking lot during his deposition against Boeing. His suicide note said "I can't do this any longer" and "I pray Boeing pays." His attorneys stated he was in "very good spirits" and they "didn't see any indication he would take his own life." Police concluded suicide from chronic PTSD related to the whistleblower case.

CONSPIRACY THEORIES: Barnett had told a friend "If anything happens to me, it's not suicide." Widespread conspiracy theories alleged Boeing had him killed, though police investigation, fingerprint analysis, ballistics, and video surveillance all supported the suicide finding. His family blamed Boeing for creating the conditions that led to his death.