Our Spitfire Replica

Our goal is simple: to make the legendary Spitfire accessible to those who dream of flying one.

At Kunarle Aviation, we share your passion for a full-size, high-performance, and authentically powerful warbird. Our goal is simple: to make the legendary Spitfire accessible to those who dream of flying one.

Originally built during wartime, the Spitfire was designed for combat effectiveness rather than long-term maintainability. With an operational lifespan measured in mere dozens of missions, these aircraft relied on dedicated squadrons of mechanics and depot technicians for continuous upkeep. Many components were difficult to access, replace, or service, and the airframe was not engineered for extended use beyond its immediate wartime role. Today, the few remaining airworthy Spitfires require substantial resources, both in manpower and financial commitment, making ownership and operation impractical for most aviation enthusiasts.

As time passes, the number of flying Spitfires continues to dwindle due to natural attrition and the challenges of restoration. Despite the tireless efforts of dedicated preservationists, only a limited number remain in the skies. With historical significance and unparalleled desirability, these aircraft now command values exceeding USD $5 million, particularly those with combat history.

For those fortunate enough to own a Spitfire, operational challenges persist. Spare parts are scarce, sourced from increasingly depleted inventories dating back over 60 years. The soaring value of these aircraft has made insurance costs prohibitively high, placing ownership beyond the reach of most pilots, even those with considerable means.

At Kunarle Aviation, we are building a true Spitfire, not a scaled-down imitation, but a full-size, fully capable aircraft that captures the essence of the original. Our mission is to bring the legendary Spitfire experience within reach of dedicated pilots and aviation enthusiasts, providing an opportunity to own and fly an authentic warbird without the overwhelming financial and logistical burdens of an original.

Pricing

Pricing is based on firm costs for components already developed, while parts still in development are subject to tentative pricing.

All kit prices are listed in Australian Dollars (AUD), FOB Sydney, NSW, Australia. As development progresses and components are sourced or manufactured, tentative pricing will be adjusted accordingly.

Please note: Pricing remains flexible at this stage and will be refined as the build advances.

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Why an Amateur Built Spitfire?

Building an amateur-built aircraft is a significant investment of time, money, and effort. If you are dedicating months or even years to such a project—along with substantial financial resources and hard work—what will you ultimately achieve? Will the end result be a small, low-performance aircraft limited to 100 knots? A cramped two-seater susceptible to light turbulence? Or a showpiece designed more for aesthetics than for the joy of flying?

At Kunarle Aviation, we offer an alternative—an opportunity to create something truly exceptional. Imagine a full-size, 1400HP warbird that is not just a machine, but a living piece of history and a reflection of your passion.

The Evolution of the Amateur-Built Spitfire

The concept of an amateur-built Spitfire dates back to Clive du Cros, who developed a wooden replica inspired by the original Spitfire prototype K5054, which first flew in the UK in March 1936. Working alongside Ray Hilbourne, a retired De Havilland engineer known for his work on the Mosquito and Vampire, du Cros meticulously hand-drafted the plans and built an airframe designed for lightness. To power the aircraft, he installed a V12 Jaguar engine, which, despite being underpowered, successfully took the aircraft into the skies.

Building upon this foundation, American aviation restorer Russ Harmuth later re-engineered the design to accommodate the original Spitfire powerplant. He selected an Allison V-1710 engine, but the airframe was designed to also fit a Rolls-Royce Merlin, staying true to the Spitfire’s legendary heritage. Structural enhancements further strengthened the aircraft to withstand an ultimate load of 10G.

Bringing the Spitfire into the Modern Era

At Kunarle Aviation, we have taken this remarkable design into the modern age, integrating advanced CAD/CAM technology to optimise construction and enhance precision. By utilizing CNC routing and modern materials, we have streamlined the building process while maintaining the aircraft’s authenticity and performance. For example, constructing an elliptical wing traditionally required a dedicated jig for each individual rib—a time-consuming process. Our refined approach allows us to manufacture a full set of wing ribs with exceptional efficiency, significantly reducing build time while preserving structural integrity.

With Kunarle Aviation’s innovative design approach, building a Spitfire is no longer just a dream—it’s an achievable reality. Whether you seek the thrill of high-performance flight, the fulfillment of craftsmanship, or the honor of preserving aviation history, our Spitfire replica offers an unparalleled experience.

Still Interested?

The primary difference between the original Spitfire and Kunarle Aviation’s Spitfire lies in materials and production methods. While the original was manufactured from metal by hundreds of factory workers using sophisticated wartime production tooling, our version is crafted using aircraft-grade wood and composites. This choice is not a compromise but a practical and superior solution for amateur builders. Wood and composite materials are easier to work with than metal, requiring only basic tools and well-understood construction techniques. These materials also offer significant advantages, including greater fatigue resistance, flexibility, vibration dampening, and noise reduction, contributing to a more comfortable and durable airframe. Additionally, unlike metal, wood and composite structures can be machined, formed, and repaired with relative ease, simplifying both the construction process and long-term maintenance.

A Proven Legacy of Wooden Aircraft

The strength and viability of wooden aircraft structures have been well demonstrated throughout aviation history. The Hughes H-4 “Spruce Goose,” still the largest aircraft ever built, was constructed entirely from wood and remains an engineering marvel. The de Havilland Mosquito, one of the fastest and most versatile aircraft of World War II, was also built almost entirely of wood, proving its capability in combat as a bomber, reconnaissance aircraft, and night fighter. Similarly, the de Havilland Vampire, Britain’s first post-war jet fighter, featured a wooden fuselage, showcasing the continued advantages of this material even in high-speed flight. These legendary aircraft confirm that wood is not just a viable option—it is an outstanding material for lightweight, high-performance aviation.

Construction Techniques

Kunarle Aviation’s Spitfire is built using well-proven construction methods that balance strength, durability, and ease of assembly. The fuselage structure incorporates aircraft-grade hoop pine and plywood, with four substantial fuselage beams that anchor the V-12 engine while connecting the fuselage and wings into a solid, load-bearing structure.

The aircraft’s shape is defined by 18 fuselage frames composed of hoop pine, plywood, and end-grain balsa, ensuring the classic Spitfire curves are faithfully recreated. The wings are designed for strength and aerodynamic efficiency, featuring 19 CNC-cut plywood ribs and two large laminated hoop pine and plywood spars to provide a rigid yet lightweight structure capable of handling high-speed flight and maneuvering loads.

Modernised Ply-Balsa-Ply Sandwich Skin

To accurately reproduce the sleek, flowing lines of the Spitfire, we employ a ply-balsa-ply sandwich skin construction technique, first perfected on the Mosquito. This method significantly enhances stiffness and strength while keeping weight to a minimum. The core consists of a quarter-inch vertical grain balsa sheet, bonded on both sides with one-sixteenth-inch plywood skins, resulting in a lightweight yet highly durable exterior. By bonding the skins directly onto the aircraft, we eliminate the need for large molds or fixtures, streamlining the construction process while ensuring a flawless, ripple-free surface.

Additionally, we are exploring an alternative ply-foam-composite skin structure that may further optimise weight savings and ease of construction.

Performance and Structural Strength

The Kunarle Aviation Spitfire is designed to be one thousand kilograms—one ton—lighter than the original Mk IX Spitfire while maintaining an ultimate load stress rating of 10G. This weight reduction, combined with the power of the Allison V-1710 V12 engine, translates to exceptional acceleration, an improved climb rate, and enhanced maneuverability. The aircraft’s turning performance, low-speed handling, and takeoff distance will also surpass those of the original, making it a remarkably responsive and pilot-friendly warbird.

Power and Propulsion

Our Spitfire is engineered to handle at least 1,400 horsepower while ensuring structural integrity. While the Rolls-Royce Merlin remains an option for those who wish to install one, we have chosen the Allison V-1710 V12 for its availability, reliability, and cost-effectiveness. These engines remain readily accessible, with multiple specialised overhaul facilities ensuring continued support.

To complete the powertrain, we use the Hamilton Standard 23E50 propeller hub with reprofiled 6353A-18 blades, closely matching the original Rotol propeller used on wartime Spitfires. This propeller-engine combination has been successfully used on Allison-powered Yak-3 and Yak-9 fighters, which have similar aerodynamic and performance characteristics to the Spitfire.

A True Warbird Experience

Kunarle Aviation’s Spitfire is not just a replica—it is a fully capable, full-performance warbird designed for those who dream of flying a Spitfire but have found original examples unattainable. Built with precision, authenticity, and performance in mind, this aircraft brings the Spitfire experience within reach of dedicated aviation enthusiasts and builders. This is not a scaled-down imitation or a static display piece, but a genuine, airworthy Spitfire designed for real-world flying.

If you have ever imagined yourself at the controls of a Spitfire, experiencing the thrill of its power and agility, now is your chance to make that dream a reality.