The phrase we’re all in this together resonates with every team member who works on interior projects, particularly big interior renovations. A Global that was recently completed at Duncan Aviation’s Lincoln, Nebraska, facility is one such project. Whether they’re on the floor, in the shops, at the design center, or in the sales offices, every team member who has a role on a job like this watches with pride as the completed aircraft is returned to service and flies home.
“This was definitely one of the top three interiors I’ve worked on in my 12 years at Duncan Aviation. It was truly a collaborative effort among many teams to complete this clean, classy interior,” says Cabinet Shop Crew Leader Nick Dahlberg.
Prior to buying the aircraft, the new owner had selected Duncan Aviation for the pre-buy evaluation. Pleased with how the negotiations had gone, he then opted to have Duncan Aviation completely renovate the Global’s interior. With drawings from a firm in the United Kingdom, the teams involved in this project came together to take the plans from conceptual designs to an actual interior.
“Although the designs came from an outside firm, the entire project was spearheaded and facilitated by Senior Lead Designer Mary Lee,” says Senior Sales Rep for Completions & Modifications Matt Spain. “If not for her efforts and guidance, this project would not have happened. The designer had worked on green aircraft but had never done a retrofit modification. Mary guided him and his team through the entire complex process.”
In addition to the guidance provided by Mary Lee, the Duncan Aviation Cabinet, Interior, and Fabrication shops had to find ways to create the unique design features using materials that are certified for use in an aircraft.
Controlling light lets passengers sleep when they want to or work when they need to, regardless of the time of day. The dimmable shades on this Global have no moving parts, making them durable and easy to control; once they’re energized, they darken to block the outside light or prevent glare in the cabin.
The rear bulkhead was outlined with a veneer band, and the panels were fitted into the band. The panel on the far left was painted with a process known as hydro dipping to create a hydrograph finish with a Crushed Oyster pattern. The process involves lying film across a bed of hot water, laying the panel into that so the pattern adheres to the panel, and applying a top coat to protect the finish.
The other panel was also hydro dipped and our Cabinet Shop slipped a film insert between the two layers of polycarbonate. The film dims and turns opaque when energized, providing the aft cabin privacy and darkness when needed.
A design that forms a starburst when the door on the mid-cabin bulkhead closes is the visual centerpiece of the Global’s new interior. In order to meet the designer’s specifications, the teams from the Cabinet, Interior, and Fabrication Shops had to figure out a way to create the intricate design without exceeding weight restrictions.
“Typically crafted from aluminum, the Starburst inlay would have been far too heavy if made of all metal, so we collaborated and created polycarbonate strips that our CNC Shop made,” says Nick.
“The strips, with domed tops and rounded ends, were then set into the door and matched to those inlaid in the bulkhead divider so the Starburst design aligns perfectly when the door is closed.”
Matt Spain said the Global was full of unique features, including a French-stitched seam above and below every window panel.
“These eye-pleasing details also pick up the stitching in the seats,” says Matt. “The seats, made of hair hide and perforated leather, really show off the talents and abilities of our teams in the Upholstery Shop.”
“The polished aluminum steps with black tread were designed, approved, and installed by Duncan Aviation,” says Matt. “The steps are the first things passengers notice as they approach the aircraft, and they perfectly complement the clean, eye-popping contemporary designs in the interior of this striking Global.”