InteriorWorks was contracted to provide a carpet solution when, during flight, an errant pot of coffee destroyed the existing carpet just aft of the galley, necessitating the removal of the entire carpet. Previous to InteriorWorks’ involvement, the carpet was installed as a 34’ long single piece of carpet, running from the main cabin door (in the rear of the aircraft), forward to the galley.

InteriorWorks proposed to split the carpet into three components: one right inside the main cabin door, and the other two covering the two passenger seating areas.  To join these components into one visual piece of carpet, we fabricated two cap strips, upholstered them with carpet, and sank them into the carpet so that all the carpet is on one visual plane through the aircraft. We also recessed the hook and loop that holds the carpet to the aircraft floor into the carpet underlay, to eliminate several ridges that used to run the length of the cabin.

InteriorWorks began by removing the existing floral print tone-on-tone trim panels and curtains. They were replaced with diamond quilted synthetic suede, using contrasting thread. The existing lavatory curtain was replaced with a 3 dimensional woven textile, which we specially treated to pass aircraft certifications. The flight deck seats were reconstructed using perforated leather that matched the new carpet. For a personalized touch, we digitized and custom embroidered an Aero Commander-branded item of the customer’s onto the leather of his flight deck seats.

The finished interior is sophisticated and cohesively “swift”–reflective of the owner’s energy and dynamism.

Before, with bland gray floral trim panels and curtains (visible to the left). Note that we experimented with a Pendleton Wool trim panel covering, but ultimately decided that the pattern was too bold for this interior:

After–deep hued diamond quilted suede trim panels:

After–deep hued trim panels, new lavatory curtain:

After–new flight deck seats with custom embroidered branding:

InteriorWorks accommodated these needs by suggesting a two color wool carpet with a looped pile. The two color blend assures the greatest camouflage of dog hair and dirt, while the looped pile prevents loose fuzz balls (normally associated with wool carpet) from forming. The updated carpet dramatically reduces the negative effects of weather and pet shedding, and lends the aircraft as a whole a more modern and clean feel—enhancing moods on those grey NW winter flights!

Before–dated, easily stained carpet that highlighted dog fur:

In progress:

Progress–carpet installed:

After–new hard-wearing cabin carpet:

The Aero Commander’s owner was pleased to receive the aircraft back in service ahead of schedule and under budget. He later returned for more cabin updates with InteriorWorks–stay tuned for a later post detailing updates to the sidewalls, cabin textiles, and flight deck seats.

Before, with worn and bland carpet:

After, with new carpet installation:

Additionally, 14 wood accessories were designed, engineered, and constructed for placement throughout the cabinet to aid in the organization and convenience of the aircraft owners and staff. Each accessory features felt undersides so as not to slide during flight, or scratch table surfaces in the aircraft. These containers and accessories were all meticulously constructed to custom specifications, to provide a seamless look throughout the aircraft.

Construction of storage cabinet:

Storage cabinet installed:

Custom waste disposal:

Custom designed and fabricated wooden accessories–condiment organization with sliding drawer:

Tea caddy:

Accomplishing this task required the removal and replacement of all upholstery, side panels, carpet, headliner, and instrument panel. We designed and installed new leather and suede sidewalls and headliner, all diamond-stitched to lend a classic look. We also made new historically accurate genuine leather seat cushions. The instrument panel was replaced with a grey crinkle finish powder coat, which demonstrably enhances instrument visibility. Small details elevate the look, such as the brass trim strip retaining nuts below the windshield. The result is a refreshed and functional flight deck, which in turn enhances safety of flight.

In progress, with the new instrument panel, but old seats:

New leather seats:

Complete flight deck view of the finished cockpit (weather strip with brass nuts, diamond-stitched headliner):

Stay tuned for more InteriorWorks projects with this spectacular DC-3!

While undergoing complete mechanical and structural restoration by Aerometal International LLC (AMI), InteriorWorks designed and applied new paint with custom livery; and engineered and installed a new flightdeck instrument and overhead panel.

Before, undergoing mechanical and structural repairs by AMI:

During–InteriorWorks rendering of proposed livery:

After–Custom livery:

After–new flight deck overhead instrument panel:

After–custom laser-cut speaker grill:

 The finished result is a stunning example of a venerable WWII-era aircraft; fully air and seaworthy.

To achieve this, InteriorWorks proposed replacing the mismatched seat vinyls, curling and threadbare carpet, and cracked steering wheel. We performed extensive research to keep the restoration as historically accurate as possible–with the two requested deviations being the addition of a leather wrapped steering wheel, and the use of leather to replace the seat vinyl. The seat leather was cut on a grid with square perforation, to look like the original blue vinyl installation, and with the original-look silver piping. They were upholstered with a true “tuck and roll” technique, which looks exceptional, and also lends extra comfort to the driver and passengers.

New leather seats with tuck-and-roll upholstering:

Seat detail, leather wrapped steering wheel: 

Back seat detail:

Leather wrapped steering wheel:

 An originally installed cabinet had been removed to allow space for an additional seat, which left an awkward unfinished area, exposing the cabin door mechanism to the main cabin. InteriorWorks fabricated and installed a false bulkhead closeout to trim the area, which has the effect of hiding the door mechanism from view, as well as visually enlarging the cabin space. The existing 1970’s speckled and headache-inducing carpet was replaced with a solid-color wool carpet. All of the cabin’s leather was cleaned and conditioned.The work-scope for this project encompassed the replacement, rejuvenation, and addition of various components in the cabin.

The end result is a fresh, unified cabin that is both more functional and appealing.

Before–exposed door mechanism, un-trimmed cabin wall after a cabinet’s removal, poor quality carpet, tired leather:

After–A smooth trim panel enhances and visually enlarges the passenger cabin:

After–Attention to detail in high-wear areas with reinforced carpeting:

After–rejuvenated leather, new carpet:

After–new carpet, rejuvenated leather: