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Tally-Ho Enterprises Inc.

Name: Tally-Ho Enterprises Inc.
Address: 18799 Airport Way, Pitt Meadows, BC, V3Y2B4, CA
Telephone: +16047904472

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Tally-Ho Enterprises Inc.

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Design and building of a airworthy 80% scaled replica of the WWII Spitfire.

To replicate the look, feel, exterior and interior of the Spitfire as a categorized amateur built/experimental aircraft.

09/18/2026

Welcome back to the continuing Tally-Ho Spitfire rudder build, in the hangar fabric shop being covered. So previously we glued on the fabric as per the last post, and now we came to the really fun part of the fabric covering process...shrinking the fabric!!! This is where it really feels it's coming together. Using a calibrated iron (just a regular household iron, must be clean!) we set the temperature of the iron on a three step heating process, starting with a fairly low temperature using a very low cost thermometer calibrator. Lightly move the heated iron over the fabric starting with the center portion of the rudder on one side. Do the same section or quadrant on the other side, the idea being as you shrink the fabric it will start to exert pressure and stress on the rudder frame, and if not careful could distort or damage the structure. So moving from one quadrant to another slowly shrink the fabric on each side until you have both sides completed at the first temperature setting. Next increase the irons temperature by calibration by the required/documented amount and repeat the whole process. The third temperature increase will be the final one and repeat the same process and pattern. With this completed you should see a very nice smooth tight surface with all the wrinkles gone...hopefully. Next as can be seen with closer viewing of the last two photos, you take a pencil and start measuring out the positioning and spacing of where you are planning to start the rib stitching (this is to be determined prior as per the construction manuals)...this is really the fun interesting part...rib stitching!!! ...wait for it...that will be next!!!!

07/31/2026

Continuing on with the general description of the Spitfire MKI-V rudder fabric covering process. Using the Polyfiber system, we used Poly-Tak to attach the fabric on one side of the rudder and secure with clamps until dry, to the trailing edge, this includes wrapping the fabric around the edge as can be seen in the photos below. This provides a solid bonding of the fabric to the rudder structure, allows to align the fabric and fold it around the leading edge of the rudder, thus eliminating a seam, while continuing the fabric back again to the other sides trailing edge. To secure the fabric you will apply the Poly-Tak to complete the rough laid fabric covering and let the glue dry. You will also notice it is not necessary to pull the fabric tight, but you will want take out any folds and minimize creases as you lay the fabric down on each rudder side, since this will avoid big problems down the road. The fabric itself will be later heated and shrunk bringing the fabric to its proper level of tightness in later posts, so stay tuned and enjoy!
Just for fun I also included a shot of the Spitfire rudder showing the fabric with some pretty serious creases...not to do...but it will show to the level of what you can work out down the road if a mistake is made, and not have a panic attach!

06/26/2026

Next with the Spitfire Rudder covering, we needed to balance the rudder using lead shot. The lead shot (using the smallest you can get in order to use all the interior space as far forward as possible) is placed inside of the rudder horn by means of a cut out opening. The opening is on the under side of the horn and will be eventually covered by the fabric covering. This also allows, if required, for balance adjustments by cutting into the fabric for access, being resealed, and yet not be seen on the finish product. The shot is epoxied in place, sealed and secured into the leading edge portion of the Spitfire rudder horn. Next comes the fun part, measuring and cutting out the "Medium" grade/weight Polyfiber fabric. We want to take into consideration of using one large piece to cover both sides and minimize the number of seams. More to come, enjoy!

06/05/2026

We will start with the completion/construction of the Spitfire MKI rudder structure. The last item to be added to the rudder was the tail nav light structure. These spruce blocks were roughly shaped to size, glued in place with T88 epoxy. Once cured, final sanding to shape and drilling the hole to size to insert/mount the tail nav light component. You will also note in the same photos the trim tab hinge installation and the lamination of the rudder trailing edge, giving the structure increased strength and durability. With this necessary work completed we can now move forward with initiating the fabric work on the Spitfire rudder. Enjoy!

05/01/2026

So its time to move out of the Spitfire cockpit section and head to the tail for our next series of updates. The goal is to get the fabric on the control surfaces, elevator and rudder, documenting that process in the next series of photos and descriptions coming. Here are some top view photos of Prototype #2's elevator structure, the early mark Spitfire, showing off its ribs, newly installed cross braces and hinge points to the horizontal stabilizer. Next will be the removal of the elevator (its all one piece) from the tail section, surface cleanup (needs to be a very smooth surface otherwise it will show through the fabric work) and the trim tab nut plates to be installed permanently, tough to do with the fabric in place. Enjoy the photos!

03/30/2026

Rudder Pedal box being fitted in Prototype #2. Requires a few minor adjustments and details, but other than that it is ready for placement. View is from the pilot seat looking down and forward in the cockpit.
It's been awhile since my last post, but wanted to finish up with the previous series/posts of the construction of the rudder box before moving onto other items. Enjoy!
Oh...and check out that fully functional scaled Spitfire MKI-V throttle quadrant now mounted into its permanent position!

08/30/2025

In the following photos you will see additional crush plates being glued into position on the Spitfire's rudder pedal box. These are strategically placed for the mounting brackets, which will secure the rudder box into its proper position within the forward fuselage cockpit section. These brackets will carry the load and stresses placed on the rudder pedals during movement, which is far superior to the original design of just screwing the box to the underside of the lower longerons. It was found the weight of the box itself ripped the screws from the longerons in the original design. Thanks Les for the improvement!

07/20/2025

As we near the completion of the Spitfire's rudder pedal box structure, the brackets and pulleys are lined up and installed on the underside top deck of the box. The rudder cables will run through from the pedals through the cable slot, and over the pulleys continuing into the fuselage. Stainless steel aircraft hardware is used throughout to avoid the metal corrosion experienced previously, and resulting wood rot with the now unacceptable older design. Multiple coats of epoxy sealer is also being used on every hole drilled and aircraft grade wood surfaces, providing maximum protection from excessive moisture exposure, prolonged life expectancy of the component and providing that nice wood grain shinny look! More to come!

07/11/2025

Moving on with the installation of components for the Tally-Ho Spitfire's rudder pedal box are the rudder cables. The port and starboard rudder cables, which are connected to the pedals, run rearward over pullies through the fuselage to the rudder horn. As a result and as per the drawings, the first of the pully mounting points must be cut out on the upper portion of the rudder pedal box, using the drawings for reference, for proper placement and install. More to come as we get closer to finishing the rudder pedal box!

07/04/2025

The next stage of the Spitfire's rudder pedal box was the proper placement and mounting of all the parts and hardware. Alignment is key with the pedals/linkage/brackets/brake cylinders, lines and cable runs along with the fitting of both heel kick plates. At this point these are not yet permanently affixed but the mounting points are drilled out, sealed, checked for freedom of movement and alignment. More parts to install so more to come!

Address

18799 Airport Way
Pitt Meadows, BC
V3Y2B4

Telephone

+16047904472

Website

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