Giving new life to an old or recently purchased aircraft, or indeed one straight off the production line, requires a special combination of creativity, technology and engineering. Whether the project is internal or external, or both, completions companies must keep abreast of emerging trends in cabin configuration, connectivity, comfort, sustainability and paint, while managing owner demands against safety regulations.

No matter the scope of the work, the process is time-consuming and decision-intensive, and will have an effect on the resale value of the aircraft. Many are the airworthiness standards that govern completions; certified components must not negatively affect airworthiness, mass, balance, structural strength or safety systems. Customisations must conform to configurations specified in the aircraft’s type certificate, or under a supplemental type certificate.
BAN talked about a recent project with Duncan Aviation senior marketing comms specialist Eric Anderson, who took us through the refurb of a Falcon 2000EX at the company’s Lincoln facility:

Duncan delivers on fleet consistency

Having originally been engaged to identify an aircraft for a planned first or second quarter 2025 purchase, aircraft sales and acquisitions representative Rene Cardona closed the acquisition of the Falcon 2000LXS in December 2024. In early October, the customer’s aviation manager shared that, following discussions with their CFO, the timeline would be accelerated in order to qualify for the 2024 bonus depreciation. Cardona successfully negotiated the acquisition of the newest, lowest-total-time Falcon 2000LXS available and completed the transaction prior to year-end.

The long-time Duncan customer then elected to upgrade and modernise the company’s existing Falcon 2000EX to match the newly acquired aircraft. From the moment passengers step onboard, the goal was for the aircraft to be immediately identifiable as theirs. This consistent experience across aircraft would create a more unified fleet experience for passengers while extending the value and usability of the existing asset.

Senior lead designer Stephanie Kuhn, design assistant Lauren Burkhardt and senior completions and modifications sales representative Tracey Boesch worked closely with the customer to achieve that vision. Notably, some of Kuhn’s earliest projects involved refurbishing three of the customer’s aircraft back-to-back, establishing a deep understanding of their expectations and aesthetic preferences that carried into this project years later.

To ensure precision Boesch, along with senior avionics sales rep Jeff Simmons and interior design engineer II Mike Riley, travelled to meet the customer while both the Falcon 2000EX and the newer LXS model aircraft were available. This allowed the team to document the aircraft side-by-side, capturing measurements, hardware details and photographic references. This brought to light additional details for consideration such as new latches, lavatory door handle and towel bar, magnetised main entry door curtain panels and finishes, and ensured a high level of accuracy while reducing the risk of rework or inconsistencies during the refurbishment process.

While the intent was to replicate the LXS interior, Kuhn and Burkhardt identified opportunities to enhance select materials. The original silk carpet was replaced with a 100% wool version for improved durability and long-term wear, while retaining the same triangular geometric pattern and incorporating darker, richer tones. This update preserved the familiar look, one of the most defining elements tying the fleet together.

The refurbishment included complete a re-veneer of all cabinets using heavily figured walnut with a lighter tone. Seating was refreshed with a warmer, more modern colour palette to create a comfortable yet polished environment suitable for both work and relaxation, supporting both productivity and passenger comfort.

Throughout the cabin, modern rectangular latches with satin antique nickel plating were installed, along with new Lunel accent lighting in the PSU panels. In the cabin, the LXS wave-inspired backsplash was added to the upper sidewall at the drinkrail, using veneer trim that mirrors the curve of the table’s enclosures. Flooring selections included woven vinyl in the galley and matching carpet in the lavatory.

The flight deck was a key focus for the customer’s chief pilot, since there were vast difference between the EX and LXS finishes. Kuhn worked with the manufacturers to identify materials that would closely match the look and function of the other aircraft. The flight deck pedestal was wrapped in carbon fibre Ultraleather after a composite panel was re-shaped to achieve the required contours. This upgrade delivered a cleaner, more modern appearance, while the AirCell handset was replaced and avionics were updated.

It was no small task. Completions master specialist Cory Ebbers invested significant time and effort ahead of the work to achieve the precise look and fit, helping ensure a high-quality finish.

“Given the outcome, we feel this will definitely be an upgrade many of our 2000EX and 2000EXy clients will be interested in,” explains Boesch.

Avionics upgrades included a new Collins Venue cabin management system, LED lighting, USB charging ports and Gogo Galileo connectivity. Duncan Aviation also completed the first Gogo Galileo installation on a Falcon 2000 outside of the factory, and installed Gogo MB13 antennas in preparation for future Gogo LX5 capability.

Additional enhancements included redesigned lower sidewalls with vertical seams and trim to mimic the LXS aircraft, dark Corian countertops throughout, and thoughtful material selections that reinforce the aircraft’s comfortable corporate aesthetic.

The completed Falcon 2000EX reflects Duncan Aviation’s commitment to understanding both their customer’s operational needs and aesthetic goals, and delivering an aircraft that not only performs reliably but also provides a consistent, intuitive and comfortable experience for passengers and crew across the fleet.

The assistant VP of the client company says: “Duncan Aviation delivered an exceptional end-to-end customer experience that resulted in an interior that exceeded our expectations. The entire engagement, from initial consultations and design choices to material selection and ongoing project updates, was remarkably seamless and effortless. The two project managers assigned to our project were invaluable, guiding us at every turn with their professionalism, design knowledge, and prompt communication, making the process a pleasure. Their skill in understanding our needs, posing pertinent questions, and offering insightful recommendations was key to achieving such a superior outcome.

“The exceptional experience we had was largely due to the incredible efforts of Stephanie Kuhn, Lauren Burkhardt and Tracey Boesch. Their combined expertise in design and project management, coupled with their outstanding client service, resulted in an interior that surpassed all our expectations.

“The interior is stunning and surpassed all our expectations. While our initial aim was to replicate our other aircraft’s interior, the designer’s recommendations elevated it significantly. We received samples of proposed materials or finishes at our doorstep within a day of each suggested change, showcasing a truly first-class service.”