Overhauled IO-540 vs Factory new IO-580

[daxton238]

I’m way overdue on deciding which engine to get. I need the hive minds help. The 2 options are the overhauled IO-540 or a factory new IO-580. The price difference for the factory new IO-580 is in the $25,000-$30,000 range. The question is if the factory knew and 15 more horsepower worth that price difference? The plane will be Utah based so the more engine is enticing for the extra power.

[U2fletch]

We ordered our IO-580 in May when we received our QB kit. Shortly after putting down our deposit, Virgil called and said Lycoming was stating December for delivery. Right. We will see.
Well, it showed up today as promised. Wondering if not as many people are getting new 580's, so that helped getting it sooner? Not sure. Considering the price difference between used and new, I chose new. I used to race motorcycles and engine longevity was highly dependent on the break in method used. I like the idea of doing that myself with a brand new engine. We are also going with an SDS fuel injection and electronic ignition setup, so several parts that came installed on this motor will end up on EBay, lol.

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[TJ_Slice]

I am still 8 or 9 months away from ordering my engine, but I plan on going with Airworx for an overhauled 540. I will be using dual E-mags. I sunk the extra money into avionics.

[Battson]

When we're talking about 300 hp, 15 isn't a big difference (5%).
You can likely squeeze 5% out of an IO-540 with some fine tuning, clever air intake design, good exhausts etc. for a lot less investment than $30k USD. The 540 has a vastly bigger parts and support network, which is worth a lot more than 15 hp in my view.

Then again, do both come with the same level of warranty and factory support? if I were dropping new engine money, that would be huge on my list. A friend bought a brand new engine for his Maule, and it was back in the factory within 50 hours. Sure he lost out on flying time, but it didn't cost him a penny.

[500AGL]

I didn’t scroll up to see if this is a duplicate. the short story is every engine manufacturer has a percentage of horsepower that each engine can be within and still call it “X” horsepower.

A 540 is a great engine that ranges from 260 to 300 horsepower and the 580 is an awesome engine engine that typically starts at 315 hp and goes up.

The caveat here Is that the 540 probably averages slightly lower than the paper horsepower whereas the 580 averages slightly higher than the paper horsepower. (The marine world allows 10% delta on stated power, not sure on the aviation world)

So, suddenly instead of 260-300, you’re looking at 235-330, or more if you lycon port and polish and add some 10:1’s. That’s a big delta. (Mcardles dyno’d at 395)

Every 580 I’ve flown is strong. Really strong.

“You’ll never be disappointed with more power”

[daxton238]

Referring to Battsons comment are you familiar with warranty differences between factory new and an Airworx overhaul? He makes a good point about parts and support availability.

Also any ideas on fuel efficiency? Say I want a 140mph cruise out of an angle valve 540 or a 580. Would the fuel burn be much greater out of the 580?

[500AGL]

@daxton238,
I am unfamiliar with warranty from either, but I would assume new is more.
For fuel burn, it takes X hp to produce Y speed. While it’s not linear nor does it accommodate for different airframes, in the same airframe a 580 will burn the same rate as a 540, at the same speed.
And actually it may burn less at lower speeds due to the greater torque available.

From personal experience a C90 powered cub at 92 mph burns more than an O-360 Patrol at 100 mph.
Fuel burn rate is a direct correlation to hp output, which is directly related to throttle position, in cruise flight.

[Allen B]

I’m curious as to how you came up with the 25k difference in cost. Airworx (or plenty of others) seem to be in the 60-70k range for a 300hp 540. A new 580 is well over 100k more than that. Are we talking about a thunderbolt/experimental lycoming? I’m in a similar boat trying to plan ahead. Thanks

[U2fletch]

The price listed on the Bearhawk website is $91550 for the 580. That’s what we paid for ours.

[Allen B]

Thanks for the response. I still am not clear about the price. $91550 for a brand new certified 580? I’ve seen the price list but I was assuming that was for the YIO 540/580’s (the experimental thunderbolt, not a certified engine). A certified engine has to be a lot more than that. The Lycoming website build sheet is around 150-180k for a new crate 580 unless I’m screwing something up.

[U2fletch]

That price is for the experimental YIO-580-B1A motor

[Allen B]

This is all starting to make sense lol. Thanks!