Volare Aviation has completed the full interior and exterior refurbishment of a 2000-build Bombardier Challenger 604. Highlights of the project include the introduction of a four-place conference seating group at the rear of the cabin, technology and avionics upgrades, and the implementation of a matte green livery.
The owner brought a clear concept for the overall direction of the refurbishment. Volare Aviation’s design team then produced a series of mood boards, colour palettes and material combinations, and worked with the owner to refine them into the final scheme.
“We have so many colours, fabrics and materials to choose from, so the possibilities are endless,” said Jake Ostridge, head of design at Volare Aviation. “Sometimes an owner comes to us with a clear vision and we simply bring it to life. Other times, we work together to develop a design that reflects exactly what they’re looking for.”
Layout change
For this Challenger 604, the brief was to deliver a complete design transformation, increasing the passenger capacity whilst creating a greater sense of space and enabling greater versatility. The new layout is designed to provide a more sociable environment that is equally suited for relaxed travel.
“We were keen to add more passenger seating without compromising on comfort or feeling of space,” said Ostridge. “By introducing a four-place conference seating configuration at the rear of the cabin, we were able to accommodate more passengers while maintaining an open and spacious layout.”
Cabin technology and avionics
The refurbishment also involved technological upgrades, including the installation of a triple Collins Fusion avionics suite. Passengers have access to high-speed Starlink connectivity and a bespoke Bang & Olufsen audio system. The latter comprises four custom-integrated Beosound Emerge speakers and a dedicated subwoofer.
“The aim was to future-proof the aircraft by integrating the very best technology available, both in the cockpit and throughout the cabin,” said Ostridge.
Matte green exterior
The exterior is finished in a matte green, which presented a few challenges. “Matte exteriors are actually really difficult to get right,” said Ostridge. “The difference between matte clear and gloss clear, is if you have imperfections with gloss, you can file them out. But the thing with the matte is as it comes out of the gun, that is the finish. You can’t buff it, you can’t polish it, so if there is one problem, it has to be redone.”
“This aircraft looks completely different to everything out there,” said Ostridge. “Normally when you see a business jet, they are white with a coloured stripe, which is great, but they all look the same to me. The matte green really stands out and looks more luxurious especially in this satin finish. You walk up and you go, oh wow, this is different.”
“We’re finding a lot of our clients are choosing these monochromatic paint schemes at the moment, as they really do stand out and feel more luxurious than traditional white and coloured stripes,” Ostridge added. “I’m really looking forward to what our next project brings us.”
Bombardier Challenger models account for the majority of Volare’s refurbishment projects completed so far in 2026.
