VP Racing's Milestones: Achieving Breakthroughs in Unleaded Fuel Development

Developing a new aviation fuel is no small feat, especially when the objective is to replace a legacy product as entrenched and performance-critical as 100LL. VP Racing has boldly embraced this challenge, becoming the first company to enter full FAA evaluation for an unleaded aviation fuel through the Piston Aviation Fuels Initiative (PAFI). Every milestone achieved reflects not just technological advancement, but meaningful progress toward a cleaner, safer, and more sustainable future for general aviation.

Now in its seventh year of testing under the FAA’s PAFI program, VP Racing is on track to complete testing by the end of the year. In close collaboration with the FAA and its OEM partners, VP Racing is executing full‑scale evaluation of UL100E to confirm the fuel’s fitness for purpose and finalize validation across all required use cases. This comprehensive test program encompasses 12 engines, 9 aircraft, and more than 214 different materials used in aircraft and supporting equipment, thoroughly assessing fuel compatibility across a wide range of make, models, and operating environments.

To date, detonation and durability testing have been completed on multiple engine platforms, including Continental IO‑550‑D, TSIO‑520‑VB, TSIO‑550‑K, and Lycoming IO‑390‑C3B6, IO‑540‑K1A5, and IO‑540‑D4A5. Across the majority of these platforms, engine operation has been largely transparent, except for a limited number of configurations requiring approximately three degrees of ignition timing retard, resulting in negligible changes in power output and slightly elevated exhaust gas temperatures. Cumulatively, the engines tested, power more that 77% of the GA fleet today.

“From day one, our team understood that the only way to succeed in developing a truly viable unleaded avgas was to exceed expectations; technically, chemically, and operationally,” said Mark Walls, Director of R&D at VP Racing. “The endurance testing, the materials validation, and now the multi-aircraft flight evaluations all reflect our commitment to delivering a fuel that performs safely, consistently, and without compromise. Every test we pass brings us closer to FAA certification and, more importantly, to reshaping the future of aviation.”

To ensure real-world performance and compatibility, UL100E has entered flight testing across nine aircraft from a variety of manufacturers. These in-flight evaluations are a critical piece of the FAA approval process, capturing performance data across different engine platforms, atmospheric conditions, and mission profiles. The breadth of testing offers regulators and operators alike confidence in the fuel’s readiness for widespread adoption. Flight testing is currently underway on a Lancair Super Legacy, CCF Harvard IV, and Cirrus SR22T, with additional aircraft scheduled to enter the program very soon. Feedback from pilots and test operators across all evaluated platforms indicates that UL100E operates the same as 100LL, with normal starting characteristics, predictable power response, and no discernible differences in day‑to‑day aircraft operation. This includes successful cold‑start testing down to −13°F with no observed issues, demonstrating robust performance in cold‑weather conditions. Additional cold‑weather testing is planned in Alaska, where evaluations will extend to lower temperatures to further validate operability in extreme environments.

VP Racing’s progress has been propelled by collaboration with some of the most trusted names in chemical engineering, whose expertise has played a critical role in optimizing UL100E’s formulation for both performance and large-scale production. These strategic alliances demonstrate how innovation across industries can accelerate the path to market for transformative technologies. As UL100E advances through the final phases of the PAFI program, VP Racing is poised to redefine the aviation fuel landscape—delivering a high-octane, unleaded solution without compromise.

For more information about VP Racing and its products for racers, enthusiasts, and general consumers, visit VPRacingFuels.com

ABOUT VP RACING

VP Racing, The World Leader in Fuel Technology®, has been fueling champions in virtually every form of motorsport on land, air, and sea since 1975. VP is the Official Fuel of the series like IMSA, NHRA, SCORE, World of Outlaws, AMA Pro Motocross, MotoAmerica, SRO GT World Challenge, Champ Offroad, American Flat Track, USF Pro, NASA, and more than 60+ other sponsored series and sanctioning bodies.

VP Racing is also well-known for its full line of consumer products, including ethanol-free small engine fuels and lubricants formulated for 2 and 4-cycle outdoor power equipment, automotive additives and octane improvers, performance coolants, appearance products, apparel, and accessories sold globally through automotive, home improvement, and online retailers. The VP brand is also represented by a program for independent operators with 350+ VP-branded gas stations, car washes, quick lubes, and marinas throughout North America. For more information, visit VPRacingFuels.com

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