client case
Embraer Legacy 650
Evolution of Excellence
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use case
charter operations
sales lead
AeroVisto
interior design
AeroVisto
cooperation
TOYO AviationABS Jets
A Partnership Built on Success
When a valued charter operator returns for their second Legacy transformation, it speaks volumes about the trust built over nearly ten years. For TOYO Aviation, the decision to refurbish their latest Legacy 650 with AeroVisto was never in doubt – it was simply a continuation of a partnership that has consistently delivered exceptional results.
This Bucharest-based operator’s relationship with AeroVisto started with Cessna projects in 2016, including extensive XLS refurbishments and CJ cabin modifications. Each project built greater trust and understanding between the teams. When TOYO Aviation acquired their first Legacy in 2021, AeroVisto was the obvious choice for its transformation.
The first Legacy 600 – the eye-catching “Beauty in Grey” completed in 2022 – marked a major milestone in the partnership. It was TOYO Aviation’s first experience with AeroVisto’s advanced surface refinement technology, a solution that has proven essential for their charter operations. Three years later, that aircraft still operates perfectly, with the decorative film surfaces maintained every two years to keep the cabin in top shape despite heavy charter use.
This regular maintenance schedule highlights one of the main benefits of our Décor Film Application system: the ability to refresh and repair specific areas without significant downtime. For charter operators, where aircraft appearance directly influences customer satisfaction and booking rates, this maintainability offers a notable competitive edge. Small damages from passenger use can be fixed immediately, keeping the aircraft in showroom condition throughout its operational life.
Design Reinvention
When TOYO Aviation acquired their second Legacy 650 in late 2024, the initial brief was straightforward: replicate the successful “Beauty in Grey” design. The proven color scheme and material selection had served them well, and consistency across their fleet made operational sense.
But inspiration came from an unexpected source. While reviewing options, the owner realized our Gulfstream IV project was featured in the AeroVisto 2025 calendar. The elegant mix of rich brown leather and textured, color-coordinated surfaces in that aircraft completely captured his imagination.
This sudden design pivot might have disrupted project timelines at many facilities. However, our design team’s flexibility and extensive material library enabled rapid concept development. Within days, we reimagined the entire cabin, translating the Gulfstream’s aesthetic into the Legacy’s unique architecture. The design featured premium leather in warm cognac tones, creating an inviting yet professional atmosphere. Custom TISCA carpeting in an elegant chocolate and magnet combination was specified to offer both durability and sophisticated contrast.
Transformation Realized
The refurbishment scope went well beyond just aesthetic updates, including a full interior overhaul that covered every passenger touchpoint. Working with ABS Jets’ experienced team in Prague, our specialists carried out a transformation that required careful attention to both new installations and restoring existing components. The coordination among Switzerland, the Czech Republic, and Germany ensured smooth component flow and accurate scheduling throughout the project.
Every passenger seat was completely disassembled for reupholstering. During this process, damaged bottom cushions were discovered — an unexpected issue after years of intensive charter use. Our team promptly collaborated with Collins Aerospace to obtain replacement foam cores, restoring comfort standards. Premium leather was carefully applied to all seating surfaces, with distinctive diamond-pattern stitching on the seat centers — a detail that has become the signature of the design. The DADO panels throughout the cabin were also covered in matching leather, creating visual continuity from the floor to the window line.
The project involved installing new high-end seatbelts with gold-plated buckles to keep the design consistent. Every wooden surface inside the cabin — from cabinets to tables and trim — was given advanced surface refinement treatment with durable Décor Film. Each component was carefully prepared, with repair of damaged substrates before application to ensure a perfect finish that can withstand charter operations.
The headliner, PSU/valance panels, and windowliner panels were reupholstered with new ultraleather. Custom curtains were made to match the new color scheme. Our team performed deep cleaning of mirrors, baggage compartments, and countertops, restoring these elements to pristine condition. The cockpit panels and glareshield underwent complete refurbishment, while new carpeting and premium sheepskin seat covers improved crew comfort during long flights.
The galley and lavatory areas received new non-textile flooring, offering both durability and visual appeal for these busy zones. This comprehensive effort made sure that every surface, from the most visible passenger areas to the practical crew spaces, met the same high standards.
Exceeding Expectations
Adrian Necula, CAMO Manager at TOYO Aviation, captured the spirit of the collaboration in his message to the team:
“From the outset, this project demanded a high level of coordination, precision, and creativity. The final result not only met our expectations but in many ways exceeded them, thanks to the dedication, craftsmanship, and collaborative spirit of everyone involved. Every detail, from design conception to final installation, was handled with professionalism and care. It’s a true testament to what can be achieved when we bring together a shared vision and the right expertise.”
His feedback highlights what makes successful refurbishment projects stand out: not only technical skills but also the human aspects of partnership, communication, and shared dedication to excellence.
Long-term Value Creation
For charter operators like TOYO Aviation, this refurbishment is more than just an aesthetic upgrade. The maintainability of our advanced surface refinement technology proves particularly valuable in their operational setting. Instead of allowing gradual deterioration from intensive passenger use, they can keep their aircraft in top condition with targeted maintenance efforts. When minor damage occurs – which is inevitable in charter operations – a simple phone call activates AeroVisto’s support team, often resolving issues within days rather than weeks.
This proactive maintenance approach, starting with their first Legacy and now applied to their second, ensures both aircraft meet the high standards expected by charter clients. The consistent quality of interiors enhances TOYO Aviation’s reputation as a premium charter operator.
Partnership Evolution
As YR-TRE returns to charter service, it not only features a stunning new interior but also continues a partnership known for delivering excellence. The transformation from initial concept to flying reality in just four months, despite design changes and unexpected challenges, highlights the agility that defines modern aircraft interior refurbishment.
This project highlights what happens when Swiss and German precision meet Romanian entrepreneurship, supported by Czech technical expertise—a true European success story. For AeroVisto, it strengthens our position as long-term partners committed to our clients’ operational success.
The evolution from TOYO Aviation’s first Cessna projects to overseeing multiple Legacy transformations shows how trust and expertise build over time. As their fleet continues to expand, we look forward to supporting their success with the same dedication, creativity, and craftsmanship that have characterized our partnership from the start.
Scope of work
- Complete seat reupholstery with premium leather, featuring diamond-pattern stitching
- Bottom cushion foam replacement
- Reupholstery of a three-seater divan using textured fabric
- Cockpit seat refurbishment with premium sheepskin materials
- Flight attendant seat reupholstery
- Lavatory seat reupholstery with matching leather
- Dado panel upholstery throughout the cabin
- Windowliner panel reupholstery using ultraleather
- Reupholstery of PSU/Valance panel using ultraleather
- Headliner panel reupholstery using ultraleather
- Comprehensive Décor Film Application on all wooden surfaces
- Custom curtain production and installation
- Re-plating of all hardware from silver to gold finish
- New seatbelts with gold-plated buckles
- Complete carpet replacement throughout the main cabin, including air ducts and throw rugs
- Cockpit carpet replacement
- Non-textile flooring installation in the galley and forward lavatory
- Deep cleaning and restoration of mirrors
- Deep cleaning of baggage compartments
- Deep cleaning and restoration of countertops
- Cockpit panel and glareshield refurbishment
- On-site installation support
- Complete burn testing and certification compliance
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