New Spitfire test frame exclusive

Welcome to this latest edition of our Workbench blog and all the news, updates and modelling exclusives from the fascinating world of Airfix.

The one thing Workbench blog regulars have always been certain of over the past seven years, is that they will be the first people to hear about the very latest Airfix kit developments on blog day and throughout any given year, there will be lots of them! That proud tradition continues in this latest edition, as we re-visit arguably the most eagerly anticipated new model tooling project we have been following for many a year and the latest addition to our iconic 1/24th scale 'Super Kit' range, the Supermarine Spitfire Mk.IXc. We know that many of our readers are really looking forward to spending some quality time with this kit following its release, so we are delighted to confirm that this update will be an exclusive first look at the latest, and final test frame components, before this stunning new model tooling is released for production.

As you might expect, for a kit of this size and complexity, the parts frames are extensive, but in a further bonus for this edition, we will have the expert input of the Spitfire's designer Chris Parker-Joy to guide us through this important stage and to give us all an explanation as to what exactly we are looking at, from the man who knows best. Bringing this extensive update to a close, we will also be bringing you news of a further significant development concerning this kit, one which has historic implications not just for our new Spitfire, but also for the Airfix brand itself.

It's time to strap yourself in, clear prop and set a course for your latest Airfix blog update.

Airfix large scale Spitfire a New Year delight

A thing of beauty, our new Spitfire kit is our latest scale tribute to arguably the most famous aircraft to ever take to the skies.

For modellers and Airfix enthusiasts alike, the start of any new year is not only a time for resolutions and returning to work after a few days spent with the family, but also the anticipation of the impending launch of the latest Airfix model range and all the scale delights within. With re-liveries and re-introductions galore to stimulate our interest, the Airfix team are in no doubt as to what the most eagerly anticipated feature of any range launch is as far as the enthusiast modeller is concerned and that is the announcement of our latest selection of new model tooling projects, even though we are aware that everyone inspecting the range will probably be hoping to see their own particular favourite aircraft, military vehicle or other subject receiving the Airfix treatment. Whilst we know that no new tooling announcement will ever appeal to absolutely every single modeller out there, there was one kit project unveiled at the start of this year which potentially stood more of a chance than most of achieving such an incredible popularity feat, our new large scale Supermarine Spitfire Mk.IXc.

In a year which marks the 86th anniversary of the first flight of Spitfire Prototype K5054 from Eastleigh Aerodrome, Airfix marked our continued modelling association with Britain’s most famous aircraft with the unexpected, early year announcement of a newly tooled Spitfire kit in our largest scale for aircraft model kits, 1/24th scale. At a specially arranged event held at the Imperial War Museum’s Duxford site, delegates at our Spitfire: An icon in Airfix event had turned up expecting to hear members of the Airfix team describing the fascinating process of taking some of the world’s most famous aircraft, military vehicles, cars and ships etc, and turning them into beautiful scale kit representations of those same machines. What they didn’t know was that they were also going to be present at the exclusive unveiling of our new 1/24th scale Supermarine Spitfire Mk.IXc kit, in advance of the main 2022 range announcement, which was scheduled for the following day - they would be the first people outside the company to see our impressive new Spitfire kit and inadvertently playing their own small part in the continuing Airfix story. The scene was set for a memorable Spitfire related occasion.

For a new model tooling announcement event featuring the latest Airfix Spitfire kit project, could there possibly be a more fitting venue to be found anywhere in the world than Duxford airfield in Cambridgeshire? The then Royal Air Force Station Duxford took delivery of the first production Spitfire (K9789) on 4th August 1938, receiving further aircraft at a rate of around one each week following that first arrival, until home based No.19 Squadron became the first to be fully equipped with this incredible new fighter. The unit had previously been operating the Gloster Gauntlet biplane fighter and whilst this was an extremely capable fighting aeroplane in its own right, it could hardly have been more different to a Spitfire. This biplane fighter featured an open cockpit, fixed undercarriage and a radial engine which propelled the fighter to an impressive 230 mph. The new Spitfire was a sleek, fast monoplane design, with a fully enclosed cockpit, retractable undercarriage and eight wing mounted machine guns. Perhaps of greatest significance, the Spitfire was over 130 mph faster than their previous fighter, representing a quantum leap in aviation performance terms and posing more than a few challenges for the unit’s young pilots during their type conversion.

The unmistakable profile of the Spitfire stood for mush more than just a successful aircraft type, it came to symbolise the defiance of the British nation in the face of adversity and a determination to strive for victory!

As millions of people are fully aware, the Spitfire would go on to become arguably the most famous fighter aircraft of all time, showing its combat credentials during the savage dogfights of the Battle of Britain, before going on to serve valiantly in every theatre of conflict during the Second World War.  Produced in more numbers than any other British combat aircraft, the basic Spitfire airframe proved to be so adaptable that the aircraft would undergo significant upgrade and improvement throughout its sixteen year service life, something which allowed the fighter to be in constant production throughout the Second World War. Using what was essentially the same basic airframe, the last of the Spitfires were producing more than double the power of the first machines, with this variant's maximum take-off weight and rate of climb also doubling. 

The graceful, sweeping lines of the beautiful and instantly recognisable Supermarine Spitfire sometimes make it difficult to accept that this was actually one of the most deadly fighting aeroplanes the world has ever seen. The Spitfire also came to stand as a beacon for Britain’s defiance in the face of overwhelming adversity and the nation’s prowess in the field of aeronautical excellence. Standing the test of time, for many millions of people, the Spitfire is as iconic today, as it was ground breaking when first taking to the skies 86 years ago.

Our latest scale tribute to an aviation icon

Working in this largest of aircraft model kit scales, Chris Parker-Joy was able to incorporate an incredible amount of detail into his new Spitfire Mk.IX design, creating a fitting tribute to the enduring legacy of this aviation masterpiece.

The Supermarine Spitfire Mk.IX variant was arguably the most important mark of Spitfire in the entire production run and for this reason, it is somewhat surprising to learn that it was actually something of a stop-gap development of the fighter. The arrival of the Luftwaffe’s new Focke Wulf 190 fighter over the Western Front in August 1941 and continuing development of the Messerschmitt Bf 109 saw RAF Spitfire Mk.Vs operating over the Channel falling victim to the ‘Butcher Bird’ in ever increasing numbers and something had to be done. A major Spitfire upgrade was in development at that time, however, the Mk.VIII variant was still some way off, as manufacturing facilities prepared their tooling jigs for the new aircraft, but there was a temporary solution. One of the major features of the new Spitfire was its use of a powerful new version of the Rolls Royce Merlin engine and it was proposed that fitting this new engine to a Spitfire Mk.V airframe would give the fighter a welcome performance boost.

The first 100 Spitfire Mk.IX fighters constructed were actually Mk.Vc airframes adapted to take the new Merlin 61 two stage, two speed supercharged engine, with this combination producing a thoroughbred fighting aeroplane, one which was more than capable of challenging the FW190 and the latest ‘F’ variant of the Messerschmitt Bf 109. In fact, this new variant of the Spitfire was eventually considered so successful that this would become the second most heavily produced variant in the entire production run and if including the aircraft powered by the licence built Packard Merlin 266 (Spitfire Mk.XVI) even eclipsed the Mk.V in production numbers. With further powerplant refinement taking place throughout the production life of this variant, the first Mk.IX Spitfires started to join RAF Squadrons from July 1942, with this famous mark of Spitfire going on to see service past D-Day and into the post war era. The last major Merlin engine powered variant of the Spitfire, this ‘emergency stop-gap fighter’ actually became something of an aviation classic. 

As an aircraft type, the Spitfire is regarded as something of an aviation classic and amongst the different variants within its total production run of 22,685 aircraft (including Seafires), the Mk.IX was a fighting thoroughbred, despite the fact that it was an emergency hybrid development, required to counter the latest advances in Luftwaffe fighter development. From a scale modelling perspective, Airfix and the Spitfire have had a long and illustrious connection over the years, with various marks of the aircraft appearing in different scales since our first aircraft kit was released way back in 1955, a kit which you will not be surprised to learn was actually a  Spitfire model. Of all these various Airfix Spitfire kit representations released, for many people, our 1/24th scale Superkits were regarded as being the pinnacle of detail, modelling enjoyment and display impact and for that reason, when we announced that we would be producing a newly tooled kit in this scale, it was something of a headline grabber.

This fascinating image shows the various design stages of just one small section of the new Spitfire kit - just multiply this by 433 parts and you can see how Chris managed to invest so much time in the new Spitfire. 

The variant of Spitfire selected for this significant project was the Mark IX, a thoroughbred aircraft in every sense of the word and the second most heavily produced variant of the Spitfire, even though it was initially only intended as a top-gap introduction. Entrusted to the design expertise of Senior Product Designer Chris Parker-Joy, Chris has already provided us with a fascinating insight into the challenges he faced in taking on such a daunting project as this in the New Spitfire Introduction edition of Workbench published earlier in the year, however, as this latest update represents such a significant stage in the development of our new Spitfire, we felt that we needed his input once again, simply because he knows more about this model than anyone else.

The pictures we are showing throughout this update all feature the fourth and latest round of test frame shots produced from the new 1/24th scale Supermarine Spitfire Mk.IXc tooling and they are being shown for the very first time - over to Chris.

The first thing we asked Chris was if he would be good enough to explain what exactly we were looking at here and what stage in the development of the new Spitfire do they represent?

He told us that these are the fourth round of test frame components produced by the various new Spitfire kit tools, supplied by the toolmaker and hopefully incorporating all the various modification requests previously made by Chris. When the very first test frame components were received at Airfix HQ, Chris expected to have quite a lot of work to do, starting with a thorough assessment of the frames and resulting in a tooling report being sent back to the toolmaker. Once all the individual parts have been assessed for CAD design detail representation accuracy and moulding effectiveness, a slow and careful build of the kit parts is undertaken, keeping notes as this proceeds, knowing that the end of this process will require the writing of a comprehensive review report to be sent back to the toolmaker.

At this first stage, quite dramatic changes can be requested, as this is the first time a designer has had the opportunity to see how the work done on his computer in Margate has been interpreted by the toolmaker in the Far East. Some of these changes may come about because something he thought might work out during design didn't quite turn out the way he intended during the manufacturing process and may therefore require the CAD files to be altered, resulting in further tooling modifications. At this stage, tasks such as checking measurements, thicknesses and importantly, construction fit accuracy are also significant considerations and for a kit of this size, could result in the toolmaker having quite significant work to do prior to running the next batch of part frames.

A first look at the new 1/24th scale Spitfire Mk.IXc part frames, concentrating first on the larger component frames. Please note the substantial wing spar and its dihedral in the third image.

In the case of the new 1/24th scale Spitfire, Chris informed us that the number of tooling modification requests of different levels of complexity totalled around 250 individual points following review of the first components, with this work taking exactly 23 days from receipt of the parts to the report being sent back to the toolmaker. Interestingly for the Spitfire, which is made up of an impressive 433 parts, Chris had to produce individual tooling reports for each of the seven tools which make up this impressive new kit.

The next thing we wanted to ask Chris was regarding the impressive levels of detail incorporated into this new kit and whether internal detail in the cockpit and engine bay is moulded onto the larger parts, or designed as separate parts to be attached?

Chris told us that when he received this fourth iteration of the part frames, he was hoping to see the result of several previous requests to represent surface detail more accurately and to make some detail a little more pronounced. We were fascinated to learn that quite a few of the problems a designer has to overcome at this stage are actually a result of earlier changes he himself had requested, but are later discovered to produce knock-on issues with other aspects of the tooling or part layout. With a kit as big as the Spitfire, there was always the possibility that this might happen and in that respect, it certainly didn't disappoint - there has been quite a bit of Spitfire head scratching of late. 

From receipt of the first test frame components, Chris was not happy with how the propeller detail had been represented and despite having a wealth of research information at his disposal, asked our Lead Researcher to obtain scan data of the specific information he wanted to check, something which required him to spend quite some time back in CAD software, redesigning this particular feature of the kit. Again, these modification requests would have posed similar challenges for the toolmaker, however, this was all done in the name of accuracy and Chris is now more than happy with how this important detail has been replicated.

From a detail and accuracy perspective, Chris told us that working in 1/24th scale certainly gives a designer much more latitude, but how there are still some important parameters which must not be crossed if this pursuit of detail is not to create manufacturing difficulties. For example, you would not want to be producing components which were so fine that they are almost guaranteed to break when attempting to remove them from the frame, but similarly, you would not want to amalgamate individual parts into a single, more robust assembly when they would be much more accurately represented as separate parts to be added during construction. 

As you can clearly see from close inspection of the part frame images featured, Chris has managed to include lots of impressive detail in the design of his new Spitfire, a combination of moulded detail on some larger components and smaller parts to build up detail both internally and externally, which will all result in a beautifully accurate large scale representation of this famous aeroplane. From the impressive cockpit tub detail, to the three different wheel hub options, building this kit will not exactly follow how a real Spitfire was constructed, but it won't be too far short.

When Chris was handing the frames to our photographer in support of this feature, he described how some of the clear parts had not been polished yet and we wanted to understand what exactly he meant by this.

As we have discovered through many previous new tooling design editions of Workbench, the clear part frame of any model kit will always require the production of its own separate tool and as you might expect for a project of this size, the Spitfire clear parts frame is quite impressive. Supporting the inclusion of instrument panel detail and many smaller components, this tooling also had to include the distinctive blown canopy which was such a distinctive feature of the Spitfire's design and in this larger scale, the size and depth of these parts must have posed some challenges for the toolmaker.

You will also see that on closer inspection of frame X, parts 9 and 10 are the tip farings for the clipped wing variant of the Spitfire. Interestingly, although the Spitfire is famous for its distinctive elliptical wing, some Spitfires optimised for low flight (LF variants) had the outer sections of their wings removed and 'clipped' for a better roll rate. It is a common misconception that these aircraft had the outer sections of their wings cut off, however, the wingtips of all Spitfires were actually manufactured as separate pieces, made from wood and covered with an aluminium skin. These were attached with two large bolts and a collection of smaller screws, so there was nothing as savage as taking a saw to a Spitfire wing tip if the aircraft was to operate at lower altitudes - thank goodness for that.

This next selection of images starts with the clear parts which proved so fascinating during our discussions, followed by more frame views and more of the Spitfires 433 parts.

One of the most challenging aspects of 'clipping' a Spitfire's wings would be the repositioning of its wingtip lights, with the clipped wing version devoting the entire front section to the light/lens. This is the reason why Chris thought it more effective to produce these particular parts in clear plastic, as this way they would be much easier for the modeller to work with.

The comment about polishing the clear parts was certainly worthy of following up, because the answer is not quite as obvious as it might seem. During the course of the past seven years of producing Workbench, we have regularly seen images of models, particularly prototypes, where the clear parts are anything but clear and are almost opaque in appearance. This is not because the clear parts haven’t been polished, but rather that the tooling block used to produce them hasn't been polished - we definitely got that one the wrong way around. When the tooling is still in development and subject to change, the block used to produce clear parts is just as much subject to change as any of the other tools, it’s just that this tool will eventually be treated differently from the others.

When the designer is happy with how his clear parts have been replicated, he instructs the toolmaker to polish the internals of this tooling block (the section used to produce the parts). The production of the injection moulding tooling blocks is a fascinating process we will be covering more fully in a future Workbench Special, but the process can leave microscopic machining marks in the metal, marks which are much easier to see when producing the clear plastic parts. In order to avoid this potential problem, the clear part tools undergo a specialist and time consuming polishing process, something which can be rather expensive and is therefore something you would only do when you were completely happy with your clear parts. Chris informed us that you can actually ask the toolmaker to perform localised polishing, when you would like some parts to be clearer than others - this stuff is really clever.

With the scale Merlin engine being particularly impressive, did this present you with any particular design problems?

Building the scale Rolls Royce Merlin engine will be a project in its own right, with this aspect of the kits design posing quite a few challenges for Chris. He also went on to describe how for him, this was probably the most satisfying aspect of his design achievements. 

A quick look at frame K will highlight the fact that these parts are almost exclusively required to construct the model's Merlin engine. Chris did have some design data to refer to in the first instance, that produced during the development of our 1/24th scale de Havilland Mosquito kit, however, this was definitely just for reference and the new Spitfire's Merlin design was a completely new design. He told us that the engine ended up being probably the most complicated and most challenging aspect of the design, but in contrast, was also the most satisfying or him. The engine build almost sits apart from the rest of the build and could quite conceivably be displayed as a separate model if so desired, in much the same way a real Spitfire was built separately from its engine. The overall cost of a Spitfire to the government of the day was made up of the cost of the airframe to Vickers Supermarine and the cost of the engine to Rolls Royce, with the two coming together to create an aviation masterpiece.

Chris told us that the engine design alone took him somewhere between six and eight weeks to complete and whilst engaged in this work, he wasn't thinking about such things as tooling layout and arranging the parts, because there would be plenty of time for that later. During the design phase, his only concern was to accurately represent the Merlin engine in 1/24th scale and to split the individual components in the most logical way, but always with the enjoyment of the modeller at the forefront of his thinking.

Looking at the complexity of the design and knowing that the subject aircraft was arguably the most famous aircraft to have ever taken to the skies, we wondered if he was ever daunted by the size of the task facing him? For most of us who enjoy modelling, but have no design experience ourselves, the thought of having to tackle something like a Spitfire, with all it many details and design nuances would strike absolute fear into our hearts, particularly as there are more Spitfire experts out there than any other aircraft type? Chris told us that his experience has taught him that each design project is just a series of small steps and rather than becoming overwhelmed by the task as a whole, just concentrate on the small step at hand, knowing that it will all come together in the end. We are not sure that most of us reading this could take quite such a philosophical view if being asked to take on such a responsibility.

Having already taken up far too much of his time, the final question we wanted to ask Chris was, 'From a development perspective, what comes next for our latest 'Superkit'?

Chris confirmed that following detailed assessment of these latest part frames, the tools have now effectively been signed off and are being prepared for shipment from the toolmakers in the Far East, to the manufacturing plant. This collection of tooling blocks are both high quality pieces of engineering and extremely heavy and as such, will always be transported by sea, something which has become much more problematic over the past few of years.

The final selection of parts to inspect. If you like engaging with your build projects, then this new Spitfire kit might just be the model for you!

In summary, Chris told us that the tooling stage of a new model's development is really interesting and something which is effectively a close collaboration between the designer and the toolmaker. When it come to the design process, some parts are much easier to design in CAD than they are to replicate in tooling and some compromise had to be settled on by both parties. In contrast, some aspects of the design are easier to tool than they are to produce in CAD, so this stage really is something of a joint effort between two experts in their particular fields (our description, not Chris'). 

When it comes to the actual layout of the tooling, the designer will provide the toolmaker with a detailed, but 'open to discussion' toolplan, reflecting what he thinks would be a logical way in which to position the parts within the individual frames. The toolmaker possesses specialist knowledge of the injection moulding manufacturing process and might make suggestions as to a better distribution of parts and placement of feedgates and between them, they will come up with the most effective layout for tooling the new kit, something which was again a feature of this particular project.

Having now had the opportunity of closely inspecting the part frames for the new Spitfire, many of us will be even more determined to get our hands on one of these new kits, especially when you hear the other significant news we have to bring you - more on that in a second. For now though, could we take this opportunity to thank Chris once again for generously giving up so much of his valuable time in helping us produce this feature and for giving us his expert guidance through this fascinating later stage of his new 1/24th scale Spitfire design project. As something of a design beast, would you believe he is currently already coming to the end of another significant design project, but one which has to remain top secret for the time being. Rest assured, he will be guiding us through more Airfix design delights in the very near future.

British aviation icon to be Made in Britain!

Although we can't claim this as another Workbench exclusive (that honour went to the recent live edition of our Sprue Talk programme), we are excited to now be in a position confirm that our new 1/24th scale Supermarine Spitfire Mk.IXc kit is going to be produced here in the UK. This really is great news and a significant development for a model kit which is destined to play an important role in the future of the Airfix brand - it really is quite fitting that our latest kit association with the nation's most famous aircraft will be made right here at home.

As we speak, the Spitfire tools we have been discussing this week are in the process of being shipped to the UK and once they arrive, will be unpacked, assessed and prepared for a first test run in the production plant. This will actually be quite a nerve wracking time for all concerned, as there will still be much work to do before the model can be released for production. Starting with a thorough check of the tools for any signs of transit damage, the tools will be set up for a test run, where things such as plastic temperature, injection pressure and atmospheric conditions will all have to be assessed and perfected before a first test production batch can be run. Once the manufacturer is happy to proceed, this first batch of UK manufactured Spitfire test frames will be sent to the Airfix team, who will again closely assess every aspect of the components, comparing the parts to what they already have and making recommendations wherever necessary. Once they are completely happy and only then, the Spitfire will be released for production and this historic modelling story will be allowed to come to its triumphant conclusion.

We are really looking forward to keeping you updated with these manufacturing developments, so please keep an eye out for our next Workbench Spitfire project update.

That’s all we have for you in this latest edition, but we will be back with more project updates for you next week. As always, we are interested to hear your views on all things Airfix and particularly in relation to our Workbench blog, so if you ever feel like dropping us a quick line, please use our workbench@airfix.com contact e-mail address. 

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Airfix Workbench Team