Volare Aviation has completed a full refurbishment of a 2000 Bombardier Challenger 604, turning the business jet into a modernised aircraft with upgraded cockpit systems, a redesigned cabin, Starlink connectivity and a matte green exterior finish. The project also included a Collins Pro Line Fusion avionics upgrade and Bang & Olufsen cabin audio, with Volare head of design Jake Ostridge leading the work.
The refurbishment combined a technical and aesthetic reset aimed at extending the aircraft’s appeal in the large-cabin market. The owner arrived with a clear design concept, and Volare’s team developed mood boards, colour palettes and material combinations to refine the final specification. The cabin now features a full interior redo and a four-place conference arrangement at the rear, alongside connectivity and entertainment upgrades intended to support both business travel and passenger comfort.
The exterior finish presented a particular challenge because the matte green coating required a satin-style execution that could not rely on the usual polishing methods used on gloss paint. The result places the Challenger 604 among a growing number of older business jets being rebuilt with contemporary avionics, premium cabin technology and more distinctive visual styling rather than left to age in their original configuration.