The Duncan Download Blog: Business Aviation Advice & Observations

Five Stitches down…Six stitches across…five stitches up…six stitches across. Repeat…seven times for each row; 25 rows…80 hexagons; 160 hexagons per seat; five seats…800 hexagons, all stitched by hand.

Guided by hand through an industrial Pfaff sewing machine, Niki McClish, upholstery crew leader at Duncan Aviation's Battle Creek, Michigan, facility, diligently repeats this pattern over and over. This work could be done by a machine, but working with your hands brings out the best quality product in the end.

There are always great expectations when designing an interior of a business aircraft. Not wanting to deliver the same look typically seen, Duncan Aviation’s Design team researched high-performance automotive seats in different shapes and sizes. After several trials and experiments, the designers and upholsterers created a napkin sample with a high-contrast hexagon pattern stitched in bold red on light-colored Townsend Leather in a shade called Venetian Lace. At the same time, they added ½-inch quilt foam, giving the design a three-dimensional effect. This sample and model photos showing the seats and divan trimmed in a red Garrett leather piping were shown to the owner.

He loved it.

The first step of any aircraft interior seating project is to make the design look great on paper. The next is a testament to the skill of a talented team of upholstery specialists when they bring that seat design to life.

Many options were considered about how to complete this labor-intensive project, including seeking an outside vendor to machine-stitch the pattern. In the end, quality control and time constraints kept the job in-house.

“It was an easy decision really,” says Multimedia Designer Ken Reita. “We knew by doing the work here at Duncan Aviation, we maintained strict control of the quality and could work easily within the time constraints of the project. But honestly, it was the level of workmanship and the skill of the Duncan Aviation upholstery team that sealed the deal.”

Before the first piece of leather was cut, Niki McClish, upholstery crew leader, and her team had to overcome the constraints of the dynamic certification. The certified 16G seats required critical load areas (seat cushion and back) to have a specific type of foam and density. Ken plotted out the seat design using vendor data and Niki’s input. The rigid, geometric shape allowed for a more computer-aided design, helping Ken to create a very realistic model with correct pattern placement when scaled to actual size.

Man Vs. Machine

The hexagon pattern is a pretty straightforward design, but the strict geometric shape required patience and a critical eye to keep the entire seat pattern symmetrical from side to side and top to bottom. Any inconsistencies would be glaring up next to the straight piping that accented each seat.

To guarantee this symmetry, the pattern was laid out on the leather and stitched at the same time as the foam. It was important to do this step by hand because foam allows the leather to shift easily during the sewing process. A machine is not capable of checking its work. If left unattended, the leather can and will move, requiring the entire piece to be re-stitched, wasting valuable time and expensive leather.

This was a hands-on project where the personal touch made a huge impact in the end. Another example is the odd-shaped headrest, which is wider at the top than the bottom. Stretching and wrapping the leather around the foam shape with the company logo centered without wrinkles or gathers takes time and the care of an expert’s hand.

High quality is found in the details, details that are lost if work is done by a machine.

It Takes A Team

No one person can take credit for the quality of workmanship on these luxurious seats. “It took the entire team to make it happen,” says Niki. “Everyone was excited to tackle a different type of project. We had big discussions about our process, communicated well, and stayed focused.”

These seats were a big challenge when compared to the typical aircraft seat. They were labor-intensive, but they also required a high degree of focus to ensure quality and consistency. The starting point came with the seat foam team creating five shapes that were exactly alike. From these shapes, the leather patterns were created and cut from the best parts of the leather. Pattern makers stitched the foam to the leather and cut the patterns. Several team members stitched the pieces together creating inserts and cushions.

Although complicated, the project went smoothly. Other than a few adjustments along the way, they had no major setbacks. Niki is proud of her team. “Everyone took their job seriously and put their best foot forward. We turned out a great product.”

When the final seats were lined up next to each other in the shop, they looked like carbon copies of an original. The careful modeling, precision stitching, and exact construction were worth the extra time and effort it took.

For nearly 30 years, Duncan Aviation has led the industry with custom completions solutions for a large variety of business jet cabins. Our designers are experienced in creating stunning aircraft interiors that meet the needs of aircraft operators as well as the restrictions that are often placed on such small spaces. Beautiful designs are combined with expert production, innovation, and quality. The result is a cabin experience unlike any other.

The modern aircraft cabin requires a combination of quality material with the latest technology and in-flight entertainment. When planning for your cabin experience, it’s important to keep in-mind things such as configuration, management systems, seat design, lighting, interior soft goods, connectivity, and so much more.

Aircraft cabins designed and customized by Duncan Aviation include a wide variety of features and benefits.

• Wireless Bluetooth allows you to make the most of devices brought on-board.
• LED lighting provides the most versatile aircraft lighting options.
• Connectivity solutions provide Internet, VPN, and streaming access.
• In the service galleys, ovens, microwaves, wine coolers, and coffee makers all combine into the beautiful design and functionality found in the cabin.
• Aircraft noise is lessened by new technologies and insulation sound proofing packages.
• Purposefully designed seating allows for better ergonomics
• And gorgeous cabinetry provides elegance and functionality.

Your aircraft cabin should make you feel at home. Comfort, productivity, and identity are all key components of the perfect cabin experience. With Duncan Aviation, that dream can be realized.

“Once he saw the 3D renderings with the materials selected, he signed the contract, and we got to work.” Rachael Weverka, Duncan Aviation Lead Designer

Duncan Aviation Lead Designer Rachael Weverka recently worked with a customer who wanted extensive renovations on his G-V (Gulfstream V). He was a designer’s dream in that he was easygoing, knew what he wanted, and was open to her ideas. But before he would sign a contract, he wanted to see how the colors, patterns, and materials all came together.

Rachael worked with Dan Ryba, one of Duncan Aviation’s Multimedia Illustrators, who produced 3D renderings of what an aircraft would look like with the proposed design.

“I’d met with our customer at his hangar, and he was anxious to get started on the project because he had an upcoming flight overseas and needed the renovations completed prior to that trip,” says Rachael. “Once he saw Dan’s 3D renderings with the materials selected, he signed the contract, and we got to work.”

Completions and Modifications Sales Representative Joep Cuppens also worked on the project, which included complete custom-designed exterior paint.

“We can’t all envision what a finished project is going to look like, and the 3D renderings really take away the guess work,” says Joep. “Several of my customers have asked for them, and they’re delighted by what they see. Even better, they’re especially pleased that the finished product looks like the 3D renderings.”

Photos: Left-before interior refurbishment; Middle-3D rendering; Right-after interior refurbishment

Carpet conundrum

The time frame for the workscope was a bit tight, and Rachael immediately ran into a potential delay.

“The owner liked the concept of his existing carpet but wanted to change it slightly for an updated look,” says Rachael. “Unfortunately, the existing carpet required all hand-stitching, which adds quite a bit of time to the manufacturing process. We knew that wasn’t an option, so I redesigned it to be mostly machine-made with some custom overtufting for the pattern.”

After discussing the predicament with the carpet manufacturer, Rachael was told if she created the computer templates for the repeating patterns that she had designed, they could make the carpet according to her specifications. She created the templates and sent them to the manufacturer. Using those templates, the machine that stitched the carpet incorporated Rachael’s patterns, and the manufacturer was able to make and deliver the carpet on time, keeping the project on its tight schedule.

It’s all in the details

In addition to paint, the exterior renovations included new steps, which were a unique design with their polished aluminum panels for the risers and black step tread. The mirrored finish is quite striking, and the customer loved them!

Rachael’s designs made big changes to the interior of the aircraft, right down to the smallest detail. For instance, the faucet was a standard faucet that needed to be updated to match the new interior. Rachael had a faucet in mind; it was one she’d used on another G-V.

“This new faucet is a lot like the one that’s commonly used on many aircraft but is constructed to be more durable,” says Rachael.

The new black Corian countertops served as perfect complements to the veneer with its dark grain, and the eye-popping cream accents kept the cabin from appearing too dark. The black pinstriped divan brought in some masculinity, and the soft, cashmere-covered pillows at every seat provided warmth and contrast.

For extra comfort during overnight flights in and out of the United States, Rachael found a company that makes custom linens, pillows, and foam beds that are contoured to each seat.

“The big challenge for this project was the time frame; we wanted to meet the original delivery date so the customer could use this aircraft for an overseas flight,” says Rachael. “With the quick decisions by the owner, and the incredible efforts of all of the team members who worked on this aircraft, we were able to deliver on time. The owner ended up not being able to go on his overseas trip, but the aircraft was ready if he needed it. Instead, he ended up taking delivery in time to make multiple flights to evacuate his family ahead of Hurricane Irma.”

Spring 2018 Duncan Debrief

You can read more about this and other articles in the 2018 Spring Duncan Debrief. 

When it comes to comparing aircraft maintenance quotes, you should be more concerned about what is not listed than what is.

When comparing maintenance quotes from different MRO (maintenance, repair, and overhaul) facilities, there are a staggering number of variables to consider. It is always unwise to assume the final number on each proposal represents the same level of detail. You should always be asking, ‘What does the quote include?’

To help make this process easier, we have compiled a list of questions and discussion points to help you get the details behind the numbers. This is not an all-inclusive list, but it is a great place to begin.

Here are some things to begin the proposal conversation with your sales rep.

Airframe

• Is the interior R&R included? This is often required to gain access below the cabin floor.
• What about paint touch-up? And if so, is touch-up completed by spray or brush?
• Are there state taxes on parts and labor? Consumables and freight charges? Are they included?
• Are support services like NDT, machining services, hydrostatic testing, included?
• Is tool rental included or an additional charge?

Avionics

• Are engineering fees included?
• Are any additional mods required to complete the workscope, like relocating antennae?
• Does the proposal include just the baseline package or does it outline optional features of the system being installed?
• Is the MRO including other recommended options based on feedback from other operators who have installed the system?

Paint

The number of variables that impact a quote for paint and interior completions work is nearly inexhaustible.

• In addition to the base paint quote, does the proposal include painting the entry air stair?
• Does that include replacing the step tread or masking around it?
• How many stripes and stripe colors are included?
• Are metallic stripes an up-charge?
• Is there design support if the paint scheme is changing?
• What are the options if you request a custom or second base color, wing color, tail color, or logo?
• Is painting of the wheels and landing gear included?
• What is the warranty?

Interior

Aircraft interiors is an area where it can be difficult to gauge the extra effort and care that might go into the project but that isn’t clearly represented by a number. Clarify if your interior proposal includes:

• Is the foam replaced during the seat upholstery or just the dress covers?
• What type of material is being quoted for upholstery of the divan, leather or fabric?
• Is rewebbing of the seatbelts included in the upholstery of the seats and divan?
• If it is a partial interior, and the leather color is changing, are all the leather items quoted for recovery (curtains, entry door shrouds, lavatory seat, etc.)?
• Is the carpet being replaced hand-made or machine-made? Is the carpet pad being replaced and if so, is the new pad being installed equivalent to the existing pad or does it provide additional thermal or acoustical qualities?

Engine

Always provide your logbooks up front. Doing so will get you an accurate quote on Service Bulletins, life-limited component replacements, and required Airworthiness Directives.

For non-program engines determine what level of service is being quoting. If only quoted the lowest minimums available for the engine, you can bet you will end up paying more in the end. Always ask the MRO to be up front about the expected expenses and the parts and other components that typically need replacement.

In addition to the base engine overhaul price, ask if the quote includes:

• Service Bulletin status
• Life-limited component replacement
• Airworthiness Directives
• Shipping charges
• Discrepancies

Landing Gear

Landing gear quotes can be offered in a variety of pricing structures. NTE (Not To Exceed) is the most popular and the structure used most often at Duncan Aviation. With NTE, you are provided with the maximum quote and an assurance your final bill will not exceed that quote. Often, the final bill is under the NTE price.

Other options are Firm Fixed and Standard. With Firm Fixed, you are provided with the final bill before your gear arrives. It comes with a no bill-back guarantee, regardless of the condition of the gear. Standard Pricing includes all labor required to perform the normal inspection or overhaul and required parts. Any discrepancies found during the inspection that require additional parts and labor will be quoted over and above.

Whichever pricing structure you select, pay close attention to the exclusions on the contract. They can add extensive additional costs not included in the quote. These include additional customer requests, optional Service Bulletins, missing or abused parts, replacement of life-limited parts, and engineering fees, if required.

When reviewing your landing gear proposal, ask the following:

• Does it include shipping costs for outsourced components?
• Are parts or other special programs included in the pricing?
• What are the contract exclusions?
• What parts are considered over and above?
• Are discrepancy and repair costs included in the labor flat rate?

You Play A Part

Evaluating the many quotes an operator receives in the course of preparing for an aircraft service event can be an overwhelming experience.

Ultimately, the success and satisfaction of a maintenance event is a team effort. You are as much a part of the team and its success as we are.

Bottom line…call and allow us the opportunity to walk you through the quote so you can better understand the proposal details as well as the ultimate workscope.

Duncan Aviation and its multi-shop capabilities can save you a whole lot of money. 

For instance, if you’re planning to refurbish your aircraft interior, consider adding an internet connection or upgrading your existing service to one with faster speeds at the same time.

For both jobs—refurbishing an interior and installing/upgrading an internet connection—your interior will need to be removed.

Typically, an aircraft is down for two weeks to install an internet connection, and it usually takes longer to refurbish an interior. Completing the projects simultaneously won’t add time to the work scope.

Combining the two projects saves on labor costs because your interior will have to be removed and re-installed only once. Performed separately, you will incur labor costs every time your interior is removed and re-installed.

When you’re ready to install new or upgrade your existing aircraft Wi-Fi, call the knowledgeable Avionics Service and Sales Representatives at Duncan Aviation or visit our web site for more information: www.DuncanAviation.aero/services/avionics-installation

The Duncan Aviation Senior Completions Designer and Team Leader Mary Lee and Multi Media Illustrator Ken Reita worked together to find a way to give passengers more headroom in the lavatory of a Challenger 650.

Using Mary’s designs and Ken’s 2D drawings, team members from the Interior, Cabinet, and Fabrication Shops extended the size of the vanity and shifted the toilet, making both more accessible to the business aircraft passengers.

In order to shift the vanity, it had to be resized, and that meant the original sink no longer fit. Team members in Duncan Aviation’s Fabrications Shop designed and machine-crafted a bigger sink from a solid piece of aluminum, where it’s now an eye-catching addition to the sleek new vanity.

Duncan Aviation has multi-shop capabilities, with experts who collaborate to conceive of, design, and craft nearly anything an aircraft operator needs. With experienced in-house engineers and certification experts, Duncan Aviation can also shorten downtimes by producing design data and STCs (Supplemental Type Certificates) when necessary.

Lavatory: Before and After

The Engineering and Certification department developed an STC for the redesigned lavatory, and we’ve now completed four redesigns. The aircraft were completed in pairs: The first two were completed and delivered, and then the second two arrived for the redesign.

“Because our Interior Shops had already completed two, they were able to deliver the second two Challenger 650s early,” says Project Manager Darrell Miller.

In this video watch the Dufncan Aviation fabrication shop design and machine a bigger, sleek new sink out of a solid piece of aluminum so it would fit in the redesigned vanity.

No detail, no matter how small, escapes the notice of Duncan Aviation team members. Earlier this year, a long-time customer from Jakarta, Indonesia, arrived with his company’s Challenger 604. To the casual observer, a custom-designed sink strainer is no big deal, but it was critical to Senior Financial Advisor for Air Pacific, Muliawan Sutanto, and the rest of the flight crew.

Muliawan explained that they eat a lot of meals with rice, and despite how carefully the attendant rinsed the dishes, tiny grains of rice still slipped down the drain, and the resulting clogs were costly in terms of time and money.

A clogged drain renders the sink unusable, and clearing the drain requires that the company put down the aircraft. As nearly everyone in aviation knows, putting down an business aircraft for unscheduled maintenance is costly in terms of lost flying time, and unclogging a drain is surprisingly expensive.

“Aircraft sinks have small strainers that cover only the drain, and they get blocked pretty quickly,” says Duncan Aviation Cabinet Shop Team Leader Matt Beaudette. “When those little strainers are blocked, the sink backs up so water won’t drain, but when you lift out the strainer to clean it off, all of those little food particles go down the drain, which eventually clogs it.”

Matt researched larger strainers and realized a strainer that fits inside the sink would trap the small grains of rice while still allowing water to drain. The problem was strainers that fit inside aircraft sinks don’t exist, so he mentioned to problem to Fabrication Shop Team Leader Bryan Hart. 

Bryan came up with a workable design, and he and his team crafted a custom strainer to fit inside the Challenger’s sink.

“We’re thrilled with the strainer, and it’ll more than pay for itself by preventing even one clogged drain,” says Muliawan. “It fits inside the sink, traps the food particles, and lifts out easily so the attendant can clean it.”

The Fall Duncan Debrief is now online. Download your copy now. 

In 2017, the NAHI (National Aviation Heritage Invitational) invited Duncan Aviation customer Joe Duke to enter his refurbished Albatross aircraft in its prestigious airplane show. Rescued by Joe in 2008, the 1954 G-111 Grumman Albatross had spent more than a quarter of a century in the boneyard at Pinal Airpark in Arizona. Joe and his team restored the aircraft to airworthy condition and painted it with glossy paint in elegant, understated colors. Then in 2015, the aircraft came to Duncan Aviation for a stunning interior transformation.

The vision and mission of the NAHI is to encourage the preservation of aviation history through the restoration of vintage aircraft to original flying condition. The Invitational promotes aircraft restoration via friendly competition, bringing valuable aviation treasures together in one venue and is a joint effort of Rolls-Royce North America Inc., the National Aviation Hall of Fame, the Reno Air Racing Foundation and the Smithsonian National Air and Space Museum.

The timing of this year’s show at the California Capital Airshow couldn’t have been better. As hurricane Irma raged through the Caribbean toward their Florida home, Joe and the Albatross were safely away from the devastating storm at the Mather Airport in Sacramento, California.

It wasn’t Joe’s first time at the show. In 2013, Joe was invited to enter the Albatross in the show, which at the time was part of the National Championship Air Races in Reno, Nevada. Judges bestowed the Howard Hughes Trophy (Large Aircraft) on Joe and the Albatross, and they also went home with the National Aviation Hall of Fame People’s Choice Award.

This time, the Albatross was awarded the Neil A. Armstrong Aviation Heritage Trophy as the Overall Grand Champion of the show. The perpetual trophy, features a plaque engraved with Joe’s name and the year the Albatross was manufactured, to be displayed in the Smithsonian’s National Air & Space Museum’s Steven F. Udvar-Hazy Center at the Washington Dulles International Airport in Virginia.

“It had been judged Best Large Aircraft in 2013,” says Joe, “This year, it was judged again and won the Overall Grand Champion.”

What made the difference?

In 2015, the Albatross flew to Duncan Aviation and was fitted with its interior, which included sound-dampening materials. The Duncan Aviation production team, following the plans of Joe’s freelance designer, Bruce Shoemaker of SDesign.aero, put in numerous passenger accommodations. The crew also built two galleys, a lav, and interior panels and installed LEDs, USB plugs, dome and task lighting, and new gaspers. They updated the cockpit with side ledges and a workstation.

Invoking the design style and materials used in the period in which the Albatross was manufactured, the interior even featured refurbished seats that were made from vintage Grumman parts. Although LEDs were used throughout the interior, the designed and fabricated adapters retained the aircraft’s vintage light lenses and switch bezels.

“The only difference was the interior completed at Duncan Aviation,” Joe says. “I think that pushed it over for the judges.”

“Finishing the Albatross interior was the perfect way to showcase the talent and craftsmanship of our Interior and Cabinet Shops,” says Duncan Aviation Matt Spain, Senior Sales Representative of Completions & Modifications. “And, now, getting to watch as the rest of the world sees and appreciates our work is a huge bonus.”

Our time-lapse video captures the progression from the pristine but empty cabin and cockpit to the newly completed interior.

The Duncan Aviation in-house professional design team has created five designs specifically for the Citation CJ3 aircraft. The five designs pair light and airy colors that make the cabin appear more spacious and open with darker, complementary colors for the carpeting and lower sidewalls. The beautiful yet neutral hues pull together rich textures, maintenance-friendly materials and subtle patterns that will appeal to most operators and passengers.

“The lighter colors in the upper fuselage help expand the feel of the cabin and transition to a darker base,” explains Rachael Weverka, the Duncan Aviation designer who created the collections. “The patterns add interest and variance to the design without being overwhelming.”

Two of the collections are very neutral and the remaining three options work in more gray, taupe and cream, respectively.

Operators can combine the interior refurbishments with a Rockwell Collins Pro Line Fusion flight deck upgrade and have their aircraft back in service with the best turntimes in the industry.

 “With the CJ3 Fusion flight deck upgrade installations, we anticipate that operators will want to look at refurbishment options,” says Suzanne Hawes, Duncan Aviation Completions Sales Rep. “Since turntime is always important, we want to ensure efficiency with interior materials. The materials in these packages will be in stock and ready to go.”

In addition to the interior collections, Rachael also designed six fresh paint schemes for the CJ3, consisting of five original, Duncan Aviation-exclusive designs.

To see these collections and three-dimensional drawings of how these interiors will look, visit www.DuncanAviation.aero/cj3interiors.

We recently expanded our 3D design capabilities by adding Dan Ryba, a multimedia artist specializing in 3D illustrations, to our in-house aircraft interior and paint design team. Ryba joins Ken Reita and the design team, who have  been creating innovative designs for clients on all makes of aircraft.

Both Reita and Ryba are focused on creating 3D conceptual illustrations for clients who are looking to make interior and exterior modifications to their aircraft.

“These 3D renderings save a great deal of time and money, so they’re popular with all of our clients , internal sales and production people,” says Ken. “Unlike with 2D drawings, we can draw from our extensive engineering database and generate accurate 3D models of the entire interior that are specific to the actual measurements of an aircraft. You can see immediately what works and what doesn’t.”

There have been times when a client  is torn between two materials. One may be darker than the other, and explaining that the darker material will give the space a dark, closed-in feel isn’t nearly as effective as a 3D image that shows exactly how the space will be perceived.

“When clients look at the illustration, they might say, ‘Whoa! The darker material is too heavy for that space. Let’s go with the lighter color.’ Or, if they really want that dark color, we can suggest other options, such as going with a lighter color on the leather seats or carpet to provide more of a contrast and get the ratio of light to dark correct,” says Dan. “It’s far better to find out on the front end before any work has been done on a project. Our clients especially appreciate being able to see exactly what they’re getting.”

The 3D models are beneficial to our production teams, too. Seeing the model helps everyone with project planning, long before any work begins.

3D Graphics In Work

“Recently, a client, interior team lead, engineer, salesperson, and I were sitting at a conference table with a 3D preliminary concept of a credenza,” says Ken. “Using the 3D model as a focal point for our discussion, we went through each modification. For the cabinet, the client wanted to see where the electronics would plug in and how they’d look sitting on the shelves. The engineer looked over the model to see how to mitigate heat build-up and where to put the ventilation and wiring. The team leader wanted to make sure the Cabinet shop could build the shelves and install pocket doors with the rounded edges and corners in the design. I was concerned about retaining the beauty and balance of the design. With all of our input, we figured it out pretty quickly, before any production was started.”

There are other times when it’s not convenient for the client to meet face-to-face, so the Duncan Aviation sales team can request a 3D image of the design for the client and include it in the sales package, saving everyone involved time and money.

Seeing is believing, so giving clients and production teams a visual representation of the finished aircraft, inside and out, helps prevent surprises along the way. 

For more information about Duncan Aviation’s modifications services, visit Duncan Aviation at booth #C9125 during this year’s NBAA convention from October 10-12, in Las Vegas, Nevada, or watch for announcements at www.DuncanAviation.aero/nbaa.