Duncan Aviation Aircraft Transformations

Duncan Aviation recently worked with a longtime customer to refurbish a Gulfstream IV-SP to better operate as a corporate shuttle for up to 14 passengers.

This longtime Duncan Aviation client uses a fleet of GIV-SPs that operate as vital corporate shuttles, often flying 12 to 14 people on longer international trips, says Austin Chambers, Airframe Service Sales Rep for Duncan Aviation’s Battle Creek, Michigan, location. One of their aircraft had a 96 month inspection due, which required that the interior be removed and replaced. It sported a configuration that did not have divans designed for the durability they required, nor were they the client’s preferred seating option for three adults. Duncan Aviation and the customer decided an extensive cabin reconfiguration along with the inspection was the best option for the aircraft’s mission.

The Gulfstream GIV-SP delivered earlier this year with a completely refurbished and reconfigured interior featuring 14 individual club seats in walnut brown leather. The unique configuration has all of the seats facing straight ahead towards the cockpit, similar to typical airline seating. Many of the seats feature rotating bases, allowing them to pivot 180 degrees when needed, which gives the seats the flexibility to function more like seats do in a standard corporate configuration. In the end, countless hours of planning and execution all came together for a truly beautiful and versatile finished product and another satisfied customer.

In addition to the inspection and the refurbishment, the aircraft’s workscope included a 5000 landing inspection, including replacement of the failed cap angle, and a full custom paint scheme. The company’s other two GIV-SPs also came in for heavy airframe maintenance events, full paint refurbishments, and 5000 landing inspections.

Duncan Aviation transformed this 32-year-old Falcon 900B into a personalized business jet that met the customer’s business and personal expectations.

The project’s workscope included a new paint scheme and a complete interior transformation that included a floor plan modification.

Using a Duncan Aviation STC, the aircraft was modified for high-density, 16-passenger occupancy, including eight single seats and two 4-place divans that were foamed and upholstered to appear as if they were meant for three.

The seat leather featured a light creamy color accented with a black welt cord. Embossed black leather with contrasting stitch adorned the lower sidewall.

The galley was finished with light solid surfaces and straight grain veneer applied vertically for a classic look.

The two items that had the most significant impact on the overall appearance were the modification of the drink rail design with a thinner profile, blue lighted cupholders, and the Duncan Aviation-designed PSU to give it a modern and updated look.

The flight deck received a new Universal Avionics EFI-890R Full Cockpit retrofit with FANS, Honeywell Ovation CMS, and LED Cabin Lighting.

“The Universal EFI-890 retrofit gives the aircraft all of the modern enhancements as well as situation awareness compared to the aging avionics that lacked those capabilities,” said Avionics Modifications Sales Representative Jeff Simmons. “Along with the EFI, FANS will allow the customer to now fly worldwide without restriction.

“The new Cabin Management System from Honeywell brings state-of-the-art touchscreen controls and High Definition Video. Paired with the new Alto Aviation Audio system, the cabin entertainment experience is like watching from the comfort of home,” said Simmons.

The workscope evolved to include installing a Gogo Avance L5 Wi-Fi system and API winglets.

In early May 2019, mere weeks after opening its hangar doors, the Paint Team at Duncan Aviation’s newest full-service facility delivered its first complete paint job. The Global 5000 input in mid-April to receive an eye-catching new paint scheme, with a complicated fade from metallic black to charcoal gray.

The striking paint scheme was designed by Duncan Aviation’s Designer Teri Nekuda, who had a long-standing relationship with the customer. She had shown him numerous designs before suggesting the fade, and he was immediately intrigued by her design, especially after seeing 3D renderings of the paint scheme.

Knowing his aircraft was the first paint project at the new facility didn’t deter the customer one bit. After touring the facility and meeting with the paint team, he felt everyone working on his aircraft had the skill, experience, and confidence to undertake such a complicated project.

He also found it reassuring that so many members of the Provo paint team had trained and worked for years at the other full-service Duncan Aviation facilities in Battle Creek, Michigan, and Lincoln, Nebraska.

Designed by long-time Duncan Aviation partner Tectonic Management Group, the 53,000-square-foot paint hangar is one of the greenest paint facilities in the country. Featuring down-draft airflow technology, which includes automatic monitoring and alarms, the bays can accommodate multiple aircraft simultaneously, so the paint teams can strip, sand, and paint and perform detail work on several aircraft.

What’s more, when the customer saw his newly painted Global, he was thrilled that it remained true to the vision and renderings he’d seen. He was delighted to have not only the first-completed paint project from the Provo facility, but also a truly unique and striking new paint job.

Duncan Aviation is proud to offer hydrographic solutions for interior finishes. These solutions can be used on interior components, panels, accents, and even full cabinets, depending on their size. The capabilities open up a variety of aesthetic options for interior finishes without changing cabinet veneer, and looks can include wood grain, stone, metals, as well as custom designs. These options allow shorter downtimes than traditional methods and are excellent solutions to cabinetry with settling finishes. The solutions also provide new finish options for countertops and sinks without weight restraints or engineering requirements.

The process involves an image/pattern printed on a water-soluble film that is then placed on the surface of water in a tank. Then an item, such as an aircraft countertop, is immersed into the water and the upward pressure causes the ink to wrap around and adhere to it.

Hydrographics create the ability to replicate a variety of textures and designs to an aircraft interior while providing a lightweight, durable finish at an incredible value compared to genuine materials like leather, stone, or wood veneer. Many times, the genuine products also create challenges with thickness and lack of flexibility, which add to the complexity during the construction and application phases of the refurbishment. Hydrographics nearly eliminate the need for special edge treatments and will cover the most complex shapes.

Duncan Aviation Interior experts hosted a webinar on the different options available for cabinet finishes and interior solutions, and how these options can reduce downtime and cost, while still maintaining Duncan Aviation quality. Watch now

This unique and one-of-a-kind Global Express XRS refurbishment began with two well-respected companies, Duncan Aviation and external design team Ken Fulk Inc. Since Duncan Aviation aircraft design team has experience working with third-party designers and helping them adapt their designs to the regulated world of aviation, the project flowed smoothly throughout. The owner of this aircraft worked closely with the external design team and knew exactly what he wanted his interior to look like. Duncan Aviation made that vision a reality.

Duncan Aviation Interior Completions and Modifications Sales Representative Rachael Weverka said, “This entire project was one big partnership. Both teams worked closely with the operators of the aircraft to make this one of a kind aircraft a reality.”

The moment you walk into this newly refurbished aircraft, you are taken aback by the incredible use of colors and materials. The owner wanted the aircraft to have texture, and feature bold patterns and non-conventional colors.

You are first greeted by custom, dark rich brown wood flooring in the entryway. The carpet features half leather and half wool in dark brown and black, which is a rare and unique combination. The seats have an Aston Martin super car type of design, with details embossed throughout the seat in brown leather. The headrest also has similar details, but in black leather. The galley faces have eccentric metal designs.

The sidewalls in the lavatory feature bright striping in blue, white, and black. The faucet has a beer tap design and the countertops feature a blue and white marble look. < /p>

The project also included all custom bedding/dinner and bath linens, custom throw blankets, custom pillows and custom cushions.

Not only was the interior completely refreshed, but the aircraft also received a major airframe inspection, completely new interior paint, a CMS upgrade, and new LED lighting.

Duncan Aviation created a unique piece of flying art with the refurbishment of its company Citation 560XLS. The commissioned design was created by renowned artist Nancy Friedemann Sánchez, a Colombian-American contemporary artist who has held exhibitions across the world.

The artwork of Friedemann Sánchez draws heavily on things women would historically paint, like flowers, lace, and birds. All in all, the aircraft design utilizes 23 specific aviation paint colors and completing the design required 101 rolls of painter’s tape, 75 paint mixing cups, 135 cup liners, and 288 touch-up brushes. The artist’s final two-dimensional rendition was created with brush strokes on canvas. Duncan Aviation paint layout experts then converted those brush strokes into solid paint colors that could be applied with spray. The aircraft was divided into 14 sections and a team of six would mask and unmask as needed to apply each color to the different areas.

The interior of the aircraft was updated to better complement the exterior. The Duncan Aviation team kept the veneer and cabinetry, but refurbished the headliner, the window panels, the lower sidewalls, the seats and the carpeting. The interior sports strawberry and cayenne colored leather and includes intricate embroidery. The aircraft’s unique carpet design has a cut pile with an abstract dropdown well and a design that is reminiscent of animal hide.

The flight deck of the aircraft was upgraded to the Garmin® G5000™ avionics suite. Features of the G5000 include a dual multi-sensor flight management system (FMS) and three high-resolution 14-inch flight displays situated alongside dual touchscreen controllers. Intuitive menu structures contribute to the ease of operation and straightforward user interface that gives pilots useful information at their fingertips to include weather, synthetic vision, electronic flight charts and aircraft synoptics.

To see more about this project, watch a video here:

Duncan Aviation faced a challenge to significantly reduce the overall weight of a customer’s Falcon 900EX EASy aircraft while increasing passenger capacity.

During a pre-buy inspection at Duncan Aviation’s MRO facility in Battle Creek, Michigan, a customer requested his 14-seat Falcon 900EX EASy be reconfigured to sit 17 comfortably. He also wanted the aircraft’s overall weight to drop so future round-trip flights could be completed with no fuel stops.

The final design, created by Duncan Aviation Aircraft Designer Ken Reita, required an STC and the expert help of several others to complete. Reita and Senior Duncan Aviation Completions Sales Rep Suzanne Hawes met daily with team members from Engineering, Airframe, Interior, and Customer Service to discuss ideas and compare notes.

“We regularly updated detailed spreadsheets with the weight of every single item, including coffee containers and life rafts, on that aircraft. We even took out the carpet and weighed it!” says Hawes. “We pored over that interior, coming up with savings, ounce by ounce.”

The team switched out the seat and divan frames for lighter alternatives, removed a pocket door, installed thinner carpet, and replaced the stone countertops in the galley cabinet with sleek, lightweight laminate. They also saved 50 pounds by swapping out the insulation in the headliner.

The team ultimately fit 17 seats comfortably in the cabin and shaved 374 pounds from the aircraft’s weight!

In addition to the pre-buy and complicated reconfiguration, Duncan Aviation performed an airframe 2-C inspection, EASy II avionics upgrade, and complete paint.

After weeks of research and months of negotiations, Duncan Aviation’s Aircraft Sales Team overcame a great many obstacles to acquire a Falcon 2000LX from Thailand for a long-time maintenance customer. Because the price of the aircraft was considerably less than the new owners had anticipated, they decided to make the Falcon 2000LX entirely their own by reconfiguring the cabin, installing a new interior, upgrading the cockpit avionics, installing a new CMS (Cabin Management System), and applying a custom paint scheme to the exterior.

The new CMS, a Collins Aerospace Venue, offers home-theater-quality sound and access to movies, maps, and weather information throughout the cabin. Additionally, the Venue allows control of cabin lighting, window shades, and seat positions. LED lighting was installed throughout the cabin, and passengers will also enjoy reliable, speedy in-flight connectivity thanks to the new Gogo AVANCE L5 Wi-Fi system.

In addition to replacing the PSU, headliner, window trim, and upper and lower sidewalls in the cabin, the customer also opted for striking new custom carpet throughout the cabin.

The newly designed galley featured clear glass racks in the Galley Tower, a liquor storage drawer, and all new rich, dark veneer on the galley cabinet.

Cockpit avionics included FANS (Future Air Navigation System) and CPDLC (Controller Pilot Datalink Communications), which is not currently mandated when flying in US airspace but is required for flying in the NAT (North Atlantic Tracks) and in European airspace.

The exterior pearl base coat provided not only protection for the aircraft but also a beautiful backdrop for the metallic stripes and the customer’s business logo.

Upon seeing the newly completed aircraft, the customer commented, “It’s not even the same airplane—it’s not even close! You guys touched literally everything that could have been touched, so it’s basically a new airplane!”

Duncan Aviation Designers and Interior Engineers thought outside of the box while designing this one-of-a-kind solution for operators looking for more storage.

The front lavatory space on some Falcon 900 and 2000 aircraft often remains unused for its intended purpose. However, many Duncan Aviation clients have put this area to good use by replacing the forward lavatory with a customized storage cabinet. Whether coat closet, or custom-tailored storage cabinet, or a combination, this modification is designed to fit individual needs.

Modified drinkrails transform the existing drinkrails into a modern new look by extending lower sidewalls up and reducing the drinkrail extension downward. The switch panels are moved under new lids fabricated in the top of the drinkrails with new or repositioned cup holders and new lift-assist or existing pull-out sidewall tables to update the cabin with a modern, elegant design and improved functionality. Lighted cupholders are available as an option.

Falcon 900 PSU

What happens when creativity and hands-on experience come together? Revolutionary ideas. Duncan Aviation pioneered the first custom-designed Falcon 900 PSU overlay panels as a one-piece panel upgrade for smooth, modern lines eliminating the painted metal center section.

Expert positioning of the up and downwash bulbs behind the panels reduces shadows on the ceiling and upper sidewalls, providing a consistent wash of light. Because the O2 panels, speakers, and lightboxes are secured to the aircraft and not the panel, they are lighter in weight and secured in place with unique custom brackets and quick-release latches to prevent the panel from falling during flight or heavy turbulence. The design not only updates the look, it also adds value and provides easy access for maintenance on older aircraft. Duncan Aviation has installed more than 50 Duncan Aviation-designed PSUs on Falcon 900 & 2000 aircraft.

One of the biggest tests of quality is how long something lasts. Aircraft interiors are no different. Years of constant passenger use during flight tend to wear on the function and aesthetics of interior components. Seats, tables, cabinetry and galleys tend to show wear and tear, which can date an aircraft and affect the impression it makes on passengers.

“Longevity is subjective; a lot can depend on how often the airplane is used and how many passengers are regularly on board. In addition, the longevity is based on the quality of the products used coupled with quality installation standards and processes. Of course, how well the interior is taken care of, cleaned, and maintained also plays into its lifespan,” says Duncan Aviation Aircraft Modifications Sales Manager Nate Klenke.

Case in point: Duncan Aviation completed a Gulfstream GIV in 2007 that was placed on static display at the National Business Aviation Association’s annual convention in Atlanta, Georgia. The aircraft had new paint as well as a fresh interior that showcased a multitude of industry firsts. A look at that aircraft today after 13 years of regular use, proves that its design was timeless and the interior installation and construction was of the highest quality.

Fast-forward to 2020. The GIV interior and paint have held up incredibly well, much longer than typically seen in the industry, Klenke says. Timeless design, high-quality materials, expert installation and application of the interior components combined to allow this aircraft surpass the test of time.