Terry,
It's not easy to decide repowering for me. I was happy with KAD300, simple and economical.
Also with the great help of Henry Boyd and DPMulvey from this board I enlarged my trim tabs and put back C4 prop set. Especially thousands of thanks again for Dpmulvey I emailed lots of to him about my performance datas of new tabs because he also did for his boat and gave me lots of suggestions such as the stifennings and negative angle etc.
But since I put C3 and then turned back to C4 due to the overweight of people, diesel and water from full to 3/4 tank of fuel my boat struggles to plane, altough through wind wont plane. Later the tank shows below 3/4 boat planes but in bad weather again difficult to plane.
Last weekend I leaved my boat at my winter marina for ten days and there is no current the underwater of my boat became dirty and black antifouling changed to a brown mud.
I'm not gonna haul out and pressure water to not killing the antifouling just gonna wipe with the scotchbrite's yellow side by diving.
Only I was on board, full water and fuel between full and 3/4 boat planed but didn't pass 3050-3100 rpm while must do 4000-4100 felled off plane when wave came.
So I'm started to thinking that enlarged trim tabs 40x50(cm) are good to plane but 285 hp 570 nm torque 3.6lt engine power is less to push my boat in difficult conditions. So I'm thinking to buy D6-370-DPH 370hp 850nm torque 5.5lt.
Before buying the D6 I'm gonna try to open up/tune up the injection pump to gain more hp and torque if t is possible in KAD300 because its semi electric diesel and know that the KAD31-32-41-42-44 engines would gain 30-40hp and 70-80nm more by this method. If its applicable to my engine gonna try if not start to get quotes from Volvo Penta dealers for new engine.
Even if I would repower could answer your questions about KAD300 beacuse I have 3 friends currently have KAD300 in their 280DA and 300DA's.
According to your sea trial with windy/wavy sea conditions 3100-3200 rpm is acceptable and your speed is good. But in good conditions you should(must) plane at 3000 or 2900rpm.
3900rpm is manufacturer suggested wot and if you could get it again with good mood of sea/weather dont change the props. But I suggest you to use C3 or C4 prop set. Try them with 4 people and full liquids. You must see 3900rpm and get better wot then C2 28 knot. When I put C3 with 1/4 fuel no water and water heater only me and minimum gear, clean bottom,props,tabs and leg I got 28.7 knots and with full water,fuel,heater and 8 people got 27.5 knots.
Try my suggestions and if you are happy with current prop set leave them on. You should do at 3000rpm 20knots and at leats 25knots at 3500 rpm which is maximum permitted extended cruising speed (10% less then wot)
Your fuel consumption 30 liter I guess you calculated it by refueling the tank after your sea trial while you started with full fuel. But its a little more then mine. I did last tank average 13.5LPH and it was containing 3 hours run of 2900rpm full tabs down full drive in (-8 -9 degree), 2 hours fast cruise at 3500 rpm 25-27 knots, 2 hours at 1500rpm (before kompressor kicks in) no wake zone/hull speed and 20 hours at cruising speed 3000rpm no tabs 0 +1 +2 trim. Totally did nearly 27-28 hours. You should have same range of hours.
Before planning and before 1500 rpm kompressor kicks in trim the drive (leg) fully down to -9, if it wont go -9 you must service your drive and fully deploy the trim tabs. Hit the throtle more then to 1500 rpm and you will hear the voice of kompressor is whistling and slightly raise it but dont hammer down like a gas engine. Our engine's have both compressor and turbo so you should do steady throtle opening. Then when you reach to 2500 rpm and pass it the voice changes from whistle to lion roar which the kompressor stops and turbo kicks in and the bow raise stops and as you hit the throtle through 3000 rpm bow will drop. Once you reach to 3000rpm you should run about 18-20knots and then raise the drive from -9 to 0 1 by 1 degree, once push and wait and see there is no rpm and speed drop and come to 0 degree. Then slowly fully retract the trim tabs which takes 5 seconds. After all these according to sea conditions max trim to +2 at 3000rpm.
If you want to fast cruise do the trim max +5. Do not pass +5, when you push to up button of trim it would go to beach +6 +7 but DON'T exceed +5 even if you need.
To raise the stern drive to beach range and lift range(trailer mode called in mercruiser) you have to push the red button and simultaneously up button togehter in below picture. Your trim gauge must end at 42 degree and then only red light flashes 42 disappears. If you don't have the button like below picture and have the button on the throtle lever you should force the trim up button to reach to beach range and then finally to lift range.
http://i998.photobucket.com/albums/af108/melida315/volvo penta C4 prop set/trim.jpg
Hope this gives some idea of planning and setting the correct rpm,drive and tabs.
Best regards
Melida