The SureFly Electronic Ignition: Revolutionizing Aircraft Engine Reliability and Performance
By Jeff Johnson, Published Feb 22,2025
Introduction
For decades, aircraft engines have relied on magnetos—a technology rooted in the late 1800s—to generate sparks for combustion. While reliable, these mechanical systems come with significant maintenance demands and performance limitations. Enter the SureFly Electronic Ignition Module (SIM), a modern, solid-state replacement for traditional magnetos that promises to simplify maintenance, enhance reliability, and improve engine efficiency. In this deep dive, we’ll explore how SureFly is transforming aviation, from its technical design to real-world pilot experiences—and why its current pricing makes it a compelling upgrade for today’s aircraft owners.
What Is the SureFly SIM?
The SureFly SIM is a direct replacement for one of an aircraft engine’s magnetos. Developed by a team with a proven track record in aviation innovation (including Sky-Tek starters and Plane-Power alternators), SureFly’s goal was to create a system that retains the simplicity of a magneto while eliminating its mechanical weaknesses.
Key Features:
- Solid-State Design: No moving parts, reducing wear and tear.
- Self-Contained Power: No external modules or complex wiring—just a single power connection and P-lead.
- Advanced Timing Control: Automatically adjusts spark timing based on RPM and manifold pressure, optimizing combustion efficiency.
- High-Energy Sparks: Delivers consistent spark energy across all RPM ranges, even with fouled plugs.
- 2400-Hour TBO: Eliminates the need for 500-hour magneto inspections, saving time and costs.
Current Pricing: Is the SureFly SIM Worth the Investment?
As of Feruary 2025, the SureFly SIM is priced as low as $1,995.00 USD (direct from SureFly’s official distributor’s website), with slight variations depending on distributor promotions or bundled installation packages. This represents a lower upfront cost compared to PowerUp or Slick magnetos, the long-term savings in avoided maintenance and fuel efficiency make Surefly a financially sound upgrade for many pilots.
Cost Breakdown:
- SureFly SIM Unit: $1,695.00 (base price) 4 cylinder.
- Installation Labor: ~$200–$500 (2–3 hours for most mechanics).
- Accessories: Optional power conditioners (e.g., Tach 2 signal converter ($257) may add to the total.
For owners facing upcoming magneto overhauls (typically $650–$1,100 every 500 hours),plus labor and shipping, the SIM’s 2400-hour TBO and elimination of recurring inspection costs can offset the initial investment within 2–3 years.
Why Replace a Magneto with SureFly?
1. Maintenance Simplification
Traditional magnetos require regular inspections, overhauls, and annual adjustments due to mechanical wear. The SureFly SIM, with its solid-state electronics, removes these burdens. Pilots report zero maintenance outside of annual inspections, aside from checking for oil leaks.
2. Improved Engine Performance
- Smoother Operation: The SIM’s precise timing control reduces engine vibration, particularly during lean-of-peak (LOP) operations.
- Easier Starts: Cold and hot starts are quicker and more reliable, thanks to a fixed 0° timing at low RPM and increased spark energy.
- Fuel Efficiency: Some users report up to 8% lower fuel consumption in cruise, attributed to optimized timing.
3. High-Altitude Advantages
Unlike magnetos, which can struggle with arcing at altitude, the SureFly maintains consistent spark energy, improving performance in thinner air.
Installation Insights
Installing a SureFly SIM is straightforward for experienced mechanics, typically taking 2–3 hours. However, there are critical considerations:
1. Power Supply
- The SIM requires a clean power source. Most installations wire it directly to the battery’s hot side via an inline fuse.
2. Compatibility with Engine Instruments
- Some installations require a Tach 2 device ($257) to convert the SIM’s signal for legacy tachometers.
- Electronic engine monitors (e.g., MVP-50) may need resistor adjustments to read RPM accurately.
3. Timing Configuration
The SIM can be set to fixed timing (per engine data plate) or advanced timing (up to 38°), depending on FAA approvals for the airframe.
Real-World Pilot Experiences
Case Study 1: Mooney M20K
A Grumman pilot with a O360A4K reported smoother LOP operations and easier hot starts after installing SureFly.
Case Study 2: Diamond DA40
A DA40 owner observed an 8% reduction in cruise fuel burn after switching to SureFly, with no loss in airspeed. In-flight mag checks revealed smoother operation on the SIM compared to the retained magneto.
Challenges Reported:
- RPM Display Issues: Pilots using older digital tachs noted RPM dropout during mag checks, resolved with Tach2 installation.
- Early 24 Volt Sensitivity: Early SIM models were prone to resetting during power fluctuations, but this was mitigated in later revisions.
SureFly vs. Electroair: A Head-to-Head Comparison
While SureFly dominates the market for simplicity, Electroair remains a competitor. Here’s how they stack up:
| Feature | SureFly | Electroair |
|---|---|---|
| Installation Complexity | Simple (2–3 hours) | Complex (requires manifold pressure sensor, extra wiring, firewall penetration, new gear assembly on crankshaft) |
| Cost | $1,995-$2,195(SIM only) + labor | $2,715–$4,550 Kit $295 Ignition Switch (system + labor) |
| Timing Control | RPM/MP-based | Altitude-variable |
| Certification | Broad AML-STC for single-engine | Limited to specific engines |
Verdict: SureFly excels in cost-effectiveness and ease of installation, while Electroair offers finer timing control for performance enthusiasts.
Addressing Common Concerns
1. “What If the Electrical System Fails?”
SureFly requires power, but retaining one magneto ensures redundancy. Dual SIM installations (now FAA-approved with a backup battery) eliminate magnetos entirely but add some complexity.
2. “Is It Worth the Cost?”
At $1,995 plus labor, the SIM pays for itself over time by avoiding magneto IRANs ($650–$1,100 every 500 hours). For a typical owner flying 100 hours annually, breakeven occurs within 3–4 years.
3. “Will It Work on My Engine?”
SureFly supports most Lycoming and Continental engines. Turbocharged and twin-engine approvals are pending FAA review.
Order Your SureFly Today – Free Shipping Available!
Get your SureFly Electronic Ignition today at Grumman-Parts.com.
- ✅ Authorized SureFly Reseller Since 2019
- ✅ Free Shipping on ALL Orders!
- ✅ Dedicated Pre-Sale & Post-Sale Support
For questions, call Jeff Johnson at 540-309-6427 or email sales@grumman-parts.com.
Conclusion
With prices starting at $1,695.00 USD (as of 02/22/2025), the SureFly SIM represents a paradigm shift in aviation ignition technology. By combining reliability, simplicity, and measurable performance gains, it offers a compelling upgrade for pilots tired of magneto maintenance. While the upfront cost may seem steep, the long-term savings in fuel, maintenance, and operational smoothness make it a wise investment for forward-thinking aviators.
For owners weighing the switch, the choice boils down to this: embrace 21st-century efficiency or stay tethered to 19th-century mechanics. The sky, as they say, is no longer the limit.
References
For further reading, explore discussions on Mooneyspace, BeechTalk, and SureFly’s official site.
About the Author:
Jeff Johnson owns Grumman-Parts.com, which was established in 2018 and has long been an advocate for the Grumman aircraft community.
As the proud owner of a 1975 AA5B Grumman Tiger, he has first-hand experience installing and flying with the SureFly Electronic Ignition. Jeff has been an authorized SureFly reseller since 2019. He is known for exceptional customer service, offering direct access by phone and email for both pre-sale and post-sale support.
📞 Call/Text: 540-309-6427
📧 Email: sales@grumman-parts.com
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