If 100 aircraft owners read this blog, I’m certain there will be 100 different opinions on the following subject. Based on my purpose, environment and mission, this is how I (eventually) came to the decision to use a traditional dual magneto ignition system for the Bearhawk 4 Place I am currently building.
From the time I started considering the Bearhawk 4 Place quick build kit, I was determined to install a dual electronic ignition system on the IO-540. I thought, why not? All modern cars use electronic ignition systems. Even the FAA has certified a few electronic ignition systems for certified built piston aircraft. At least partially, with a mag on the other side. So of course my engine should have EI. Yes, I want better engine starts. Yes, I want a smoother running (happier) engine. Yes, I want the improved fuel burn. After all, magnetos are ancient history! Come on people, get with the times!
So I set out to learn more about the Light Speed Engineering solid state EI system (lightspeed-aero.com). Klaus Savier, President, LSE, LLC, has done a phenomenal job designing and engineering his EI systems. With 20+ years in service and a great track record, along with Lycoming’s tacit approval of the Light Speed EI on their Thunderbolt engine line (by factory pre-drilling the flywheel for the crank sensor) made for a convincing argument to use this EI system on my IO-540.
Then, I took a harder look at both the P-Mag (Emagair.com) and SureFly (surefly.aero) magneto replacements. P-Mag offers a full featured electronic ignition upgrade with a built in power back-up (alternator). Simply swap out the existing traditional mag with the P-Mag. The SureFly magneto replacement is similar to the P-Mag, without back up power (uses ship power).
With this information, I’m now leaning towards P-Mag or SureFly EI’s over the Light Speed, mostly because of the ease of installation and all in one units. Unlike Light Speed that requires multiple satellite components; crank sensor, multiple coil packs, ignition modules with suggested mounting locations on the cabin side of the firewall and, recommended cooling fans. Oh, and don’t forget the additional 12V back-up battery (another 10+ pounds). P-Mag and SureFly require much less real estate, additional stuff and weigh less. I liked that.
At the time of this writing, P-Mag is only available for 4 cylinder Lycoming and Continental engines. They claim to be developing a 6 cylinder version and have a multi year waiting list. So that ruled out the P-Mag.
At 2019 AirVenture, Lycoming introduced their FAA Certified 6 cylinder electronic ignition magneto replacement, white labeled and manufactured by SureFly. Flaking out again, I now began considering a single SureFly EI on one side, with a traditional mag on the other side. Why only one SureFly? I just could not get comfortable with two first generation 6 cylinder SureFly mag replacements. Starting with one SureFly seemed like a safer approach. (Like P-Mag, SureFly has also been offering a 4 cylinder version for a several years, and beat P-Mag to the 6 cylinder market.)
Ok, so if a single SureFly (left side), and a single traditional mag (right side) would be my latest brain child, specifically which traditional magneto should I go with? Well, the Champion Aerospace Slick Mag is the most common choice, and I could not find an argument against it. So I called Champion and spoke to Joe Logie. Joe is extremely knowledgeable. I explained my pinball journey leading to my phone call with him. He asked my mission with the IO-540 and the Bearhawk. I explained that I was not building a race plane and one of my greatest concerns was overcoming hot starts. Joe told me about their Champion SureStart Booster on a dual magneto system. With the key switch on “start” isolates the left (retard) signaling the SureStart Booster to send 25,000 volts to those plugs. When the switch returns to “both”, both mags are running at the normal 6 to 8,000 volts per plug. Joe said I would enjoy hot starts on the 2nd or 3rd blade, every time. I was sold.
I have now finished installing 2 mags on the 540. My ignition system consists of the 6393 retard mag on the left side, and the 6350 plain mag on the right side. 5/8” M6002R Ignition Harness. The SS1001 SureStart Booster isolating the left mag on the start. And, finally, I installed Tempest UREM38S fine wire spark plugs. I did not go with Champion plugs. That’s a story for another day…
I originally thought I would use an electronic ignition system on the Lycoming IO-540. Today I discuss why I turned 180 degrees and decided to go with magnetos.
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