This might be a fantasy, but what other options are there for a drop in IO540/550 ‘modern’ replacement ?
Copied from PabloSniper Mundo & Tecnologia Facebook page
Twin Rotax 916 Power Package Concept
A Modern Replacement for Legacy IO-540 / IO-550 Engines
Summary
We would like to develop a dual-engine Rotax 916 power package designed to replace traditional IO-540 and IO-550 installations. The goal is to deliver equivalent or superior power, built-in redundancy, and excellent high-altitude performance — all while keeping weight and required airframe changes to a minimum.
A key requirement of the project is that the entire assembly must fit the same engine mount footprint used by IO-540 and IO-550 engines.
Additionally, the overall length of the two Rotax engines installed in tandem is very close to that of an IO-540 or IO-550, making this concept physically compatible with existing cowlings and firewall spacing.
Why This Concept Makes Sense
Modern Performance With Redundancy
Two Rotax 916 iS engines produce 320 hp, allowing this package to directly replace the 310 hp IO-550 found in aircraft such as the Cirrus SR22 — with the added benefit of turbo-normalized power maintained at altitude.
Similarly, a pair of Rotax 915 iS engines deliver 282 hp, making them a modern replacement for the 260 hp IO-540 commonly used in aircraft such as the RV-10.
Comparable Installed Weight
Although each Rotax engine is lighter, the full assembly — engines plus the shared shaft system — should be considered practically equivalent in installed weight to an IO-540/550. This keeps CG and structural considerations close to existing standards.
Efficiency, Fuel Flexibility & Lower Operating Costs
Rotax engines offer exceptional fuel efficiency, smooth operation, fully electronic engine management, and — importantly — the ability to run on automotive gasoline (MOGAS).
This means the kit could be applied to any aircraft currently using an IO-540 or IO-550, providing a modern, fuel-flexible alternative with significantly lower operating costs and easier global fuel availability.
Few Additional Modifications Required
The design goal is a clean installation requiring few additional changes, making it practical for OEMs and retrofit applications.
Matching both the engine mount geometry and the overall length envelope of the IO-540/550 is central to this concept.
What We Are Looking For
We are seeking a strategic partnership to co-develop a complete, modern engine package capable of replacing the aging IO-540 and IO-550 families with efficient, redundant, altitude-capable powerplants that fit existing engine mounts and appeal to both new aircraft manufacturers and the retrofit market.