The Art of a Global Express XRS Refurbishment

In this podcast, Duncan Aviation Marketing Specialist Eric Anderson sits down with Lead Designer Emily Krawczak and Completions and Modifications Sales Rep Adam Bruce to talk about this bold, masculine, and striking Global Express XRS that was recently refurbished at their Battle Creek, Michigan facility...

AvBuyer  |  21st September 2021
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No stranger to unique aircraft refurbishments, a long-time Duncan Aviation customer wanted his aircraft to be bold, masculine, and striking, much like his Citation X that the Duncan Aviation team refurbished 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.

 

Global Express XRS on snow


View the full image gallery here

Paint

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,” Krawzcak said. 

“The careful planning of our paint experts made it all possible. The aircraft certainly commands attention, and this has been one of my favorite 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,” Krawczak said. “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 over 211 hours with layout, used seven rolls of transfer material and 13 rolls of paint mask to complete the aircraft’s exterior transformation.

Interior

The contrasting light and dark colors of the exterior are consistent with the interior and share a consistent theme.

Completions and Modifications Sales Rep Adam Bruce said that this one-of-a-kind interior was highly customized 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,” Bruce said. “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 based on the inspiration in the original image the owner provided. The team was able to put together samples from vendors based on the images and designs from Krawzcak. The carpet captured exactly what the owner wanted.

Because carbon fiber is so expensive and difficult to work with, the owner opted for a hydrographic carbon fiber look on the credenza top, lower galley front, drink rails, and card tables.

Krawczak says that hydrodipping is great because it is cost-effective, can be completed in less time, and is fully customizable because there are no limitations.

Critical to the success of the Duncan Aviation Finish Shop is the mechanization they developed for the hydrodipping process. The mechanical arm, which is used to dip components, makes the 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. To watch a video of the process in action, go here: https://www.duncanaviation.aero/videos/innovative-hydrographic-solutions

The bulkheads were painted a gorgeous high-gloss piano black, which Krawczak said is gaining popularity as customers are leaving a matte design trend behind.

They also changed the doors on the galley to a standard cabinet door, where when you push them, they open and slide in.


Global Express XRS refurbished interior


The Final Product

The owner was extremely happy with how his aircraft turned out, as is the entire Duncan Aviation team.

“We started working on this project long before we even saw the aircraft,” Krawczak says. “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.”

More information from www.duncanaviation.com

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