All Imperial gallons unless noted as it is a British aircraft. Revision to earlier efforts now based on better information on Spitfire VIII/IX economic cruise. The idea would be to stay with the P-47, not the P-51. The brief I assume is a Spitfire escort fighter for the 8th Air Force from mid 1943 to at the latest May 1944, after that the acute need for longer range high altitude fighters goes, the RAF had Mustangs with longer ranges even without a rear fuselage tank, the USAAF had many more fighters and from September the continental airfields are open.
As of January 1944 external tanks for Spitfires being made were 30 gallon (Metal, wood, fibre) and 45, 90 and 170 gallon metal. "relevant Spitfire VIII figures from the original sources quoting maximum weak-mixture power setting as 320 mph at 20,000 ft, consuming about 1.1 gallon per minute. This corresponds with an engine setting of 2,400 rpm, +4 lbs boost (66 gallons per hour). So this seems similar. From the same source, the RAF were allocating 23 gallons for take-off and climb to 20,000 ft, and 36 gallons for 15 minutes of combat, leaving 63 gallons for cruise. This gives an endurance of 57 minutes, or a range of 304 miles, for an escort radius of 152 miles." (no reserves)
The mark VIII was 47+49 = 96 in front of the pilot, a 14 gallon tank in each wing = 124, the early IX 48+37 = 85. Under RAF rules the early mark IX range was 434 miles versus the VIII at 660 miles, or an additional 39 gallons for 226 miles, 5.8 miles per gallon at economic cruise, 170 to 200 mph, 30 minutes reserves at economic cruise would be around 15 to 17 gallons, rounded up to 20 for current purposes, given it is unlikely all fuel tanks could be fully drained.
Interestingly the mark VIII pilot's notes mention a 26 gallon rear fuselage tank. Morgan and Shacklady talk about an 18 gallon Mareng bag in each wing for later mark IX, plus 33 or 41 gallon rear fuselage tanks. We know 75 (high back) or 2x33 (or 1x66) (low back) gallon tanks were fitted but these tanks like that of the Mustang needed to be partly emptied to improve stability and probably further emptied before entering combat.
Fuel management, the notes say take off was using the main tank, then at 2,000 feet
a) no drop tank but rear tanks filled, switch to the rear fuselage tanks until empty.
b) drop tank, no rear tanks, switch to the drop tank until empty
c) drop and rear fuselage tanks filled, change to rear tanks until only 30 gallons left in them, then switch to drop tank until empty then back to rear tanks.
Starting with the imaginary longest range Merlin Spitfire fighter version, 96 Gallons in front of the pilot, 36 in the wings, 75 behind the pilot internal, total 207 gallons. Burn 45 gallons of the rear fuselage fuel outbound. That leaves 96+36+30 = 162 gallons on board entering combat at maximum radius, allowing 36 gallons for combat and 20 gallons for reserves leaves 106 gallons, enough for 514 miles at 320 mph at 20,000 feet, outbound fuel available 90 gallons external + 45 gallons rear fuselage = 135 gallons, less 23 for warm up and climb leaving 112 gallons. Nice theoretical balance but you would need the ability to refill the internal tanks from the external ones. And it ignores all the ways range is lost. I suggest start with subtracting about 10% from the theoretical radius for real life operations, what would be good to see is an 8th Air Force P-51 fuel load planning document compared to the official fuel consumption performance figures and then apply them to the Spitfire.
Factors causing loss of range: external tank drag, formation flying, inexperienced pilots, below average performing aircraft, the extra weight (590 pounds of fuel plus tank weights pushing that to around 650 pounds, versus the actual mark VIII, rule of thumb seems to be 1 pound of self sealing fuel tank for 1 imperial gallon of capacity, external metal tanks maybe half of that). Range gain: able to fly economic cruise for a time in and outbound, able to trade height for range inbound, the small distance covered during the climb. Overall result is more than 90 gallons of external fuel required to reach the 514 mile mark. Spitfires were later cleared to carry 1,000 pounds of bombs, 100 imperial gallons of 100 octane fuel comes in at around 711 pounds.
The third edition of the Spitfire mark IX, XI and XVI pilot's notes has rear fuselage tanks with 75 gallons (66 for "rear view" fuselages), permission from the Area Commander is needed to fill the 75 gallon tanks for special operations, while the 66 gallon tanks for "rear view" fuselages "they must not be used in any circumstances". One reason for a pair of rear fuselage tanks was to reduce fuel movement, my understanding is if the 66 gallon option = 2x33 is it was safe to enter combat after one tank was emptied but the improved elevators designed by Westland were needed to carry the rear fuselage fuel in any case. While the extra forward weight of the Merlin 60 series also helped.
Standard Spitfire VIII, 124 gallons internal minus 36 combat gallons and 20 reserve gallons leaves 68 gallons, 330 miles at fast cruise, the standard 90 gallon external fuel tank would be about adequate (23 gallons for warm up and climb, leaving 67 for range). Turning to what if territory, adding a 33 gallon tank to the rear fuselage of the mark VIII means 101 gallons available for range after combat, 160 miles to the possible radius, pushing it to 480 miles, another 33 gallons internal plus the 90 gallon external tank is 123 gallons, less 23 gallons for climb and warm up, leaving 100 gallons for range, not as adequate. It would require 100 to 120 gallons of external fuel to properly exploit the internal fuel.
According to Roger Freeman P-47 radius with relevant external fuel, nominal tank capacity / actual capacity (US Gallons)
75/84 280 miles. In use August 1943
200/205 275 miles. (part filled) In use July 1943.
108/108 325 miles. In use September 1943.
150/165 375 miles. In use March 1944
2x150/165 550 miles. This arrangement "made handling difficult"
200/215 480 miles. In use November? 1944, project initiated in October, took 34 days to deliver the first tanks.
A Spitfire VIII with a 33 gallon rear fuselage tank and a 90 gallon external would have about 350 miles combat radius (theory 407 miles less all the deductions), it would have the range to cover actual Spitfire operations in Europe, like Britain based squadrons escorting raids on the Ruhr area. If the wing tanks could be increased to add another 12 gallons per side that would push the radius towards 400 miles.
Cumulative mark VIII production to end June 1943 was 252, halve that to account for reserves, training and losses and you have 125, around 6 or 7 squadrons, 2 wings, of Spitfires able to reach around 300 miles radius under European conditions in a force able to sustain operations.
Of course first comes convincing the British that after 3 or more years of everyone wants the Spitfire, latest version, never enough, things would change so much in 1943, the P-47 would be effective, the Luftwaffe fighter force would largely pull back, the P-51 would be delayed but then take over from the Spitfire as the everyone wants aircraft, that the loss of production changing Castle Bromwich over to mark VIII was very acceptable as would any slight delay caused by fitting a rear fuselage tank.