Recreating History: WWII Spitfire Fuel Gauges Reproduced with Precision Laser Engraving

At Javik Laser Ltd, we pride ourselves on delivering precision laser marking, engraving and component restoration/recreation services for a wide range of industries — from modern aerospace to vintage aviation restoration. One of our latest projects brought history to life in the most tangible way: we recreated WWII Spitfire fuel gauge dials using our state-of-the-art 100W MOPA fiber laser and deep engraving techniques on anodised aluminium.

This wasn’t just a technical exercise — it was a tribute to craftsmanship, aviation heritage, and the durability of British engineering.

The Challenge: Restoring a Piece of Aviation Legacy

The iconic Supermarine Spitfire — a cornerstone of Britain’s air defence during the Second World War — featured a mechanical fuel gauge mounted in the cockpit. These gauges are now rare, and surviving examples often suffer from corrosion, fading, or mechanical failure. Replacing or restoring these original parts presents a huge challenge to restoration specialists, collectors, and museums.

One of our clients brought in an original Spitfire fuel gauge, with faded markings, worn paint, and a need for a closely matched reproduction. Our goal: to recreate the dial face with absolute fidelity — matching the original layout, fonts, colours, and tactile feel, while ensuring durability and longevity in operational or display settings.

Reproduction Dash Clocks

The Process: From Reference to Reproduction

Using the original gauge as a reference, we digitally redrew the dial layout, including all the original text, arc scales, and colour detailing. The gauge featured dual readings — one for fuel quantity with the aircraft “tail on ground” and the other for “normal flight” — a subtle detail we were determined to replicate precisely.

We chose black anodised aluminium for the new dial faces. This material provides an excellent contrast for deep laser etching and is ideal for long-term readability and wear resistance. Anodised surfaces also offer the added benefit of corrosion resistance — critical for vintage aircraft restoration projects or static museum displays where authenticity and longevity both matter.

Using our 100W MOPA fiber laser, we deep-etched the layout into the surface, creating a tactile, high-contrast recess that could then be hand-filled with enamel paints. This approach closely mirrors the original manufacturing process, ensuring both authenticity and visibility in varying lighting conditions.

Deep Etching with MOPA Technology

Why use a MOPA laser for this project? MOPA (Master Oscillator Power Amplifier) fiber lasers give us unparalleled control over pulse width and frequency — essential for deep engraving on anodised surfaces without excessive heat distortion or edge burn. Unlike CO₂ or lower wattage systems, our MOPA unit allows us to control the finish precisely:

Crisp line edges

Consistent depth across curved text and graphics

No melting or flaking of the anodised layer

This control is critical when dealing with heritage components where accuracy isn’t optional — it’s essential.

Before and After: A Clear Transformation

As shown in the photos above, the transformation is striking:

The original gauge is worn and murky, with flaking paint and unreadable markings.

Our reproduction is sharp, legible, and faithful to the original design — right down to the “TAIL ON GROUND” and “NORMAL FLIGHT” references, which were custom-aligned to the pointer arc.

Whether fitted into a flying restoration, static display, or collector’s piece, this dial is built to last while staying true to its wartime roots.

Applications Beyond Aviation

While this job focused on a Spitfire Mk fuel gauge, the same laser engraving and restoration techniques apply across multiple sectors:

Military hardware restorations (instruments, data plates, dial faces)

Classic vehicle dashboards and panels (MG, Triumph, Land Rover etc.)

Maritime instrumentation for restored vessels

Museum exhibits requiring authentic replicas

Bespoke control panels for aerospace prototypes or themed installations

At Javik, we don’t just mark parts — we help tell stories through precision-engineered surfaces.

Why Choose Javik Laser Ltd for Restoration Work?

We combine cutting-edge laser engraving with a deep respect for heritage craftsmanship. Our team works closely with each client to ensure not just technical accuracy, but aesthetic fidelity.

Key reasons restoration clients choose us:

High power MOPA fiber laser technology with micron-level precision

Material versatility — aluminium, brass, stainless steel, plastics and more

Custom CAD design and layout matching from original references

Durable paint-filling and finishing techniques

ISO 9001 accredited, with full traceability and quality control

Whether you’re restoring a single gauge or reproducing an entire suite of cockpit instruments, we have the tools and experience to deliver.

Let’s Bring Your History Back to Life

If you’re working on a WWII aircraft restoration, restoring classic vehicles, or curating a museum-quality replica, get in touch. We’d love to help you recreate the parts that matter — accurately, beautifully, and built to last.

For more information on Recreating History: WWII Spitfire Fuel Gauges Reproduced with Precision Laser Engraving talk to Javik Laser Ltd