RES-SYSTEM – REStrofit

Is there an alternative drive unit for the Rotax 505 engines used in the DG-400 and DG-800A due to the well-known spare parts problem? We have the answer!

As part of the ongoing electrification process, we are pleased to offer you the opportunity to retrofit your DG-400 or DG-800A with a RES system (“REStrofit”).

RES-System in general

The RES system from Solo will be installed in the DG-400 and DG-800A in a similar configuration to that used in the JS3 RES, where the system has already proven itself:

  • Engine Emrax 208
  • Expected pylon of JS3
  • 2 batteries Emectric BM384 (including charger)
  • DC/DC-converter
Current performance data JS3

Current performance data of the JS3 RES:

  • Peak power: 40kW (up to 4m/s) at 4350 rpm
  • With self-launch:
    • Climbing height with a full battery charge: 1700m
    • Maximum range: 120km
  • Without self-launch:
    • Climbing height with a full battery charge: 2000m
    • Maximum range: 157km
DG-400 and DG-800A - additional optimizations during retrofit

In addition, further optimizations will be carried out in the DG-400 and DG-800A as part of the retrofit:

  • More powerful propeller of the JS2
  • Retrofit to two-piece engine cowlings
  • New spindle drive
  • Elimination of the 4x 6V lead-acid batteries in the fuselage nose, replaced by a 12V LiFePo avionics battery
  • Removing the old fuel tank to gain space for the installation of the control electronics
  • Easy, tool-free removal and installation of batteries thanks to an innovative spring-loaded locking system
  • Optional onboard charger for charging at an electric charging station
  • Replacement of the DEI in the instrument panel with a 57 mm round instrument, which now allows larger navigational instrument to be placed in the instrument panel.
A new propeller during retrofit

With the planned modifications and components, performance data similar to that of the JS3 RES is expected; with the new propeller, performance is even expected to improve.

Thanks to the new propeller:

  • Same thrust at significantly lower rpm -> significant noise reduction and better climb performance

 

The weight of the entire system (including batteries) is comparable to that of the Rotax 505 with a full tank. Therefore, no restrictions on payload are expected compared to the current situation.

In order to cover the financial costs of design and tooling, we would like to initially offer the retrofit as an option for DG-400 and DG-800A customers. As soon as we have 5 options, we will begin development and conversion with the aim of retrofitting the first REStrofit aircraft within the next 2 years. The target price for the conversion is €67,226.89 net (€80,000.00 gross).

The conversion includes both the complete RES system, valued at around €50,000, and the complete removal of the combustion engine and installation of the RES system, right through to the acceptance flight. The removed components (engine, spindle drive, DEI, etc.) will of course remain in your possession after removal and can be sold accordingly.

No more trips to the gas station, no more refueling with 2-stroke mixture, no more exhaust fumes!

Simply plug it in after landing or remove the two batteries through the large engine cowlings without tools and take them home with you! The next day, just pull out the plane and fly! Simple engine operation; no choke, no “flooding,” no manual propeller brake!

The maintenance and servicing costs of the RES system are also many times lower than those of a combustion engine. With the conversion, you can turn your DG-400 or DG-800A into an efficient, environmentally friendly, and user-friendly state-of-the-art self-starter.

 

Future projects

In the next step, REStrofit will also be available for the DG-800B and DG-808C. There are currently no plans for a general retrofit for the DG-600M. However, we will be happy to provide a quote for an individual retrofit upon request. Parallel to the retrofit, the new DG1001 RES is in the starting blocks. The maiden flight is expected to take place in 2026. Our sales department is available at any time to provide further information and delivery slots. After successful flight testing, the REStrofit option will also be tested for other two-seater series.