Duncan Aviation’s MRO facility in Lincoln, Nebraska, has refurbished a GL-5000, updating or replacing seating, soft goods, veneers, plating, countertops and flooring.
The owner provided Duncan Aviation designer Jaime Blanken with colour preferences and reference imagery to guide the creative direction. To ensure the vision aligned with the material selections, senior completions and modifications sales representative Matt Spain travelled to meet with the customer, presenting Blanken’s curated palette.
Seeing a trend of monochromatic schemes in aircraft cabins, Blanken layered complementary textures, new dark veneer for the cabinetry, and satin platinum plating. The custom-fabricated seat coverings feature wool-blend fabric and leather. “It feels more like an upscale living space and gives the aircraft a different feel,” said Blanken. “The angled armrests add a modern edge while enhancing functionality and style.”
The custom divan is tailored in a textured fabric. Lower sidewalls are finished in an embossed tipped leather, while the upper sidewalls, PSU and headliner remained a classic, lighter grey. There is a subtly patterned carpet, and stone-replicating luxury vinyl tile flooring in the galley. The galley countertops feature Calcutta stone solid surfaces. The galley was also modified with custom storage for liquor bottles of various heights, with integrated LED lighting.
The main entry door steps were redesigned. Crafted by Duncan Manufacturing Solutions (DMS), the new one-piece modular stainless-steel step treads feature a custom design with precision-machined neoprene rubber inlays. Each step was machined, assembled and installed to deliver a durable finish designed to reduce slipping and enhance the entry experience.
The sink in the crew lavatory had a unique size and shape, so there were virtually no off-the-shelf options available to purchase. “Once Jaime located a suitable Corian colour, automated systems master specialist Kevin Jones developed a 3D model and used his extensive experience with Corian to bring the concept to life,” said Nick Dahlberg, interior cabinet shop/CNC team leader at Duncan Aviation.
Several layers of Corian were glued together and then machined to form the bowl of the sink, which was then bonded to the main countertop. “This was a method the team has been considering for some time, and given that the aircraft was originally configured this way, it felt like the right opportunity to move forward with this method,” said Dahlberg. “The team nailed it and provided a custom, one-off product for the customer.”
In terms of technology, the aircraft is now equipped with a full Collins Aerospace Venue CMS, Prizm lighting, LED lighting on the stairs and exterior, and Starlink internet. There is a custom-flip-up monitor with a hidden button inside the credenza.
The flight deck was also upgraded, with fresh paint on seat frames as well as new sheepskin and leather crew seats, headliner, flight deck curtain, upper and lower sidewalls, window trip and carpet.
