Regarding the problems and testing failures, I don't think it was ever going to happen any other way.
No aircraft has been built in quite the same way before and its a huge step from the old style of building aircraft. BUT given their military expertise, if anyone is going to pull it off it will be Boeing.
My main concerns for the 787 aren't about passenger safety, It will be a safe enough aircraft and won't be certified unless its at least as safe as any 767s or A330s flying now.
BUT.....there is going to be a big problem, and repair bill if there is a nasty tail scrape or encounter with severe hailstorm. The repairs would be more time consuming, and intensive than with the metal liners we have today.