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As the aviation industry pushes toward sustainability, Harbour Air is making waves with its innovative retrofit of a classic aircraft—the de Havilland Beaver—into a fully electric seaplane dubbed the eBeaver. This ambitious project is more than just a nod to environmental stewardship; it is a technical tour de force that blends engineering ingenuity, lean design principles, and real-world application.
Unveiled at Everything Electric Canada 2024, the eBeaver is proof that even legacy aircraft can be revitalized for a greener future. Munro’s visit to Harbour Air’s display reveals crucial insights into electric aircraft conversion and highlights the eBeaver’s potential for reshaping short-range aviation.
Engineering a Legacy Aircraft for the Future
Harbour Air’s electrification initiative began in 2019 when the team removed the original 450-horsepower R985 piston engine from a de Havilland Beaver and installed a Magnix electric propulsion system. This bold step not only replaced internal combustion with clean electric energy, but also introduced a complex integration of modern systems into a 70-year-old airframe.
Erica Holtz, Program Manager and Engineering Lead for the project, emphasized that this isn’t a gimmick. “Everything on the aircraft is electric now. There’s no fuel in it.” The aircraft uses a fully battery-powered drivetrain and is undergoing continuous upgrades toward eventual certification.
Performance Gains: More Than Just Green
Swapping out an engine is only part of the story. The electric eBeaver actually outperforms its predecessor in key flight metrics. Thanks to a more efficient propeller, a streamlined nose design, and reduced cooling drag, the power required for level flight dropped from 62% to just 41%.
This enhanced efficiency enables impressive real-world gains:
- Takeoff distance reduced from 40 seconds to 27 seconds
- Climb gradient improved from 6.7% to 14%
- Thrust increased by 300 pounds with the same power rating
Despite maintaining the original horsepower (450 hp or 336 kW), the aircraft delivers far superior thrust and control. These improvements result in a smoother, quieter, and more capable aircraft—one that retains the soul of a Beaver while embracing the technology of tomorrow.
Battery Technology and Constraints
Current batteries on the eBeaver deliver 200–210 Wh/kg, but Magnix is developing next-gen modules expected to hit 300 Wh/kg at the aircraft level—a critical leap toward commercial viability. However, battery packaging remains a constraint. Without a traditional fuel tank, all batteries must be carefully placed to preserve center-of-gravity balance.
The initial retrofit required creative engineering workarounds: four separate batteries, dual oil systems, and externally powered accessories all crammed into the nose of the aircraft. Newer engines like the MagniX 650 will integrate accessories and consolidate oil systems, freeing up crucial space for battery placement fore and aft.
Additionally, Harbour Air is collaborating with Magnix to design future battery modules around the physical dimensions of the aircraft’s original fuel bays. This bespoke battery form factor could significantly improve weight distribution and system integration.
Charging, Range, and Turnaround Time
The eBeaver currently targets a one-hour mission with reserves, translating to an 82-kilometer range—ideal for Harbour Air’s short-hop, regional flights. A key enabler of commercial feasibility is rapid turnaround, with BC Hydro installing 150 kW chargers at Harbour Air terminals.
Operating at 600 volts (to match BC Hydro’s grid), the charging infrastructure will allow for 30-minute recharges, aligning with the current turnaround time for docking and passenger loading.
This setup means Harbour Air’s electric aircraft can support a similar operational tempo as their gasoline counterparts—particularly for 20-minute tours, which are common in their business model.
Cost Considerations and Battery Lifecycle
While direct operating costs for the eBeaver are roughly comparable to fuel-powered models, battery lifecycle is a significant variable. Batteries will be replaced after 2,000–3,000 cycles or when they drop to 80% state of health.
Crucially, Harbour Air anticipates residual value for used batteries. Once removed from flight duty, they could find second lives in microgrid or stationary energy storage applications. This potential reuse is not yet factored into current cost models but represents a promising offset.
Looking ahead, the team expects continuous improvement in energy density and battery cost. As Erica Holtz noted, “The hope is once we’ve got that path blazed through with the regulators, the next set of batteries to get certified should be a lot faster.”
From Demo to Certification: What’s Next?
The path to commercial certification is a two-phase journey. Harbour Air aims to begin operations around 2027, contingent on the type certification of the Magnix motor by early 2026. The initial certification will use current-generation batteries, followed by a transition to higher-density modules as they mature.
The ultimate goal? A fully electric regional fleet. Harbour Air currently operates several Beavers and hopes to convert them all. With advancements in battery technology, they could eventually convert Otters and Caravans as well—supporting nine-passenger loads with 400 Wh/kg batteries, a target seen as achievable within five years.
Broader Implications for Sustainable Aviation
The eBeaver project demonstrates how lean engineering and smart retrofitting can overcome the barriers that traditionally limit electric flight. Instead of waiting for brand-new airframes and factory-designed EVs, Harbour Air is proving that legacy platforms can lead the charge toward decarbonized aviation.
It’s also a reminder that the key to success in electric aviation is niche targeting. Harbour Air’s short routes, consistent downtime, and coastal infrastructure make it an ideal candidate for early adoption. Not every operator can replicate this model—but for those who can, the benefits are substantial.
Final Takeaways
- The eBeaver is a model of electric retrofit excellence, combining classic aircraft charm with cutting-edge propulsion.
- Smart design choices—from optimized propellers to modular batteries—are key to unlocking both performance and commercial feasibility.
- Scalable battery innovation will determine the broader future of electric aviation, especially for larger aircraft and longer missions.
- Regulatory groundwork and operational testing today are paving the way for faster adoption and certification tomorrow.
Want More Success Stories Like This Electric Seaplane Retrofit?
Harbour Air’s eBeaver isn’t just a prototype—it’s a bold blueprint for aviation’s sustainable future. For more teardown insights, propulsion reviews, and lean design strategies in the electric transport revolution, follow Munro & Associates and subscribe to Munro Live for updates on the evolving landscape of EV engineering.