Duncan Aviation completes a Global Express XRS


Duncan Aviation has refurbished a Global Express XRS at its site in Battle Creek, Michigan, for a long-time customer. He specified a bold, masculine and striking interior not unlike his Citation X, which was refurbished by Duncan Aviation a few years ago.

While the design motif is consistent with his other aircraft, this Global Express XRS definitely stands out in the fleet and features the owner’s affinity for the arctic.

The brief for the exterior was 'arctic camo'

The brief for the exterior was ‘arctic camo’

Duncan Aviation lead designer Emily Krawczak said that she was given the direction of ‘arctic camo’ for the paint scheme, drew different designs and sent them to the owner for feedback until they landed on one that matched his vision.

“Despite regulations that stipulate how thick we can paint the layers on the exterior, we were able to achieve the layered fade and the aesthetic goals the customer wanted while staying within the requirements,” said Krawzcak. “The careful planning of our paint experts made it all possible. The aircraft certainly commands attention, and this has been one of my favourite paint projects.”

Krawczak said paint layout specialist III Dustin Noaeill spent a great deal of time on this project, working until everything was perfect. “Dustin went in knowing this project was going to be complex and difficult,” said Krawczak. “Oftentimes, he wouldn’t talk to us while he was in the midst of planning because he liked to stay completely focused while working through the many layout challenges of this intricate design. He made it look just like what was intended, and it is absolutely amazing!”

Flight controls and layout team leader Kevin McGowan said his team came up with a completion plan for this paint scheme months before the aircraft arrived, discussing what it would take to complete the work and what the steps in the process would look like. The paint team put in more than 211 hours with layout, used seven rolls of transfer material and 13 rolls of paint mask to complete the exterior transformation.

The geometric carpet is a completely custom design

The geometric carpet is a completely custom design

The contrasting light and dark colours of the exterior are consistent with the interior and share a consistent theme. Completions and modifications sales representative Adam Bruce said that this one-of-a-kind interior was highly customised to match the owner’s tastes.

“We provided several renderings and modification options before finally settling on a workscope that pushed our teams and, in the end, showcases all of our skills as a completion shop,” said Bruce. “New techniques in hydrodipping and finish work lead the way on this job.”

The owner came to the table with a good idea of what he wanted and really wanted to stick with an interior he’d seen elsewhere. The challenge was to bring the design to life while working with his budget and time limitations. The Duncan Aviation team touched everything in the interior except the countertops in the galley.

The fully custom carpet features a tone-on-tone pattern with a geometric design and was inspired by an image provided by the owner. The team was able to put together samples from vendors based on the images and designs from Krawzcak.

The interior features hydrographic carbon fibre finishes

The interior features hydrographic carbon fibre finishes

The owner opted for a hydrographic carbon fibre look on the credenza top, lower galley front, drink rails and card tables. Krawczak said that hydrodipping is great because it is cost-effective, can be completed in less time, and is fully customisable because there are no limitations.

The finish shop has developed a mechanical arm to dip components, making the hydrodipping process more consistent and manageable for larger components, such as a galley cabinet. Finish shop team leader Chris Nelson said the arm allows for the team to dip large objects with ease because it mitigates the possibility of imperfections.

The bulkheads were painted a high-gloss piano black, which Krawczak said is gaining popularity as customers are leaving a matte design trend behind. The team also changed the galley doors to a standard cabinet door, where when you push them, they open and slide in.

The company reports the owner was extremely happy with how his aircraft turned out. “We started working on this project long before we even saw the aircraft,” said Krawczak. “I’m just really happy with how everything turned out. The craftsmanship, amount of time, and the pride our interior and exterior teams put into their work really shows.”

Images: Duncan Aviation

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Izzy has been part of the Business Jet Interiors International team since its second issue, and the editor since 2011. She also edits Auditoria and Railway Interiors International. Outside of work, Izzy is rediscovering her love of art by learning how to paint with watercolors.

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