Hi Charley,
Nice to hear that you are enjoying the boat.
The D-6 is too big. Weighs a lot more and is just large.
The D-4 will fit but it weighs more as well. You can get more HP, I think it is up to 260 but that might be with extra stuff like a supercharger. If it were me I would not want to go beyond turbo and aftercooler.
I am pretty sure that the Yanmar 6LPA-STP will fit in the box. It puts out max 315 HP with a continuous rating of 255.
Another option is the Cummins/Mercruiser 4.2 EI 250. It will fit and it tops out at 250 HP.
A couple of the guys put the 4 cyl yanmar (240 horse)in a Blackman with direct drive and had excellent results.
You have issues to contend with when going up in HP.
Prop size- you don't have much room to swing a bigger prop but you can add pitch.
Shaft size- you may or may not be able to use the same shaft.
Handling- Being a direct drive it will handle differently than the I/O s like Honeygirl. Of course just because you have the HP doesn't mean you have to use it.
I always wanted to put a Cummins 5.9 in her but it would have been a very tight fit. Mostly length wise.
Anyway you look at it: it will be costly. I chose to simply enjoy my time on the water and not worry so much about getting anywhere fast.
I'm assuming/hoping that the 41A has been good to you and if you are good to it she will last a long time before getting tired. I really think it was one of the best Volvo's of that size. If nothing else just bump it a few hundred more RPMs. If it finally gives up the ghost then the decision to re-power will be a lot easier.
I lost your address but if you'd like all the dimensions for the different motors email me your address and I'll mail you my "re-power" file.
Also, if you do decide to do something you should contact Tony Athens at Seaboard Marine. He does a lot of repowers.
Peter