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Greetings.

Am starting work on a conversion and need some help getting the scale right before I dump some serious $$$ on it.

Want to turn this into a Jet Vtol:
http://www.scalehobbyist.com/catagories/Model_Aircraft/ITL00002622/product.php

The plan:
* Replace the props with Tau Hammerhead Engines and if need be shorten the overall wingspan.
* Scratch build out of parts some HB door gunners or trade off for the FW ones.
* Scratch build some pilots (or pilot pending fit)

So, I am wondering if 1/48 is going to be too large for this. Sadly I do not have the dimensions of the actual GW model so I can't compare it. Would anyone be willing to help me out?

1/48 is the closest regular model kit scale to 40k, so yes, it will be close enough.
The next two sizes for aircraft are 1/72 (too small - closer to 20mm) and 1/32 (1/35 as a rule of thumb is for ground pounder stuff. Helicopters can be found in both 1/32 and 1/35 though ) which will be too large.

Sounds good.

Will pick one up and try a test run before I make enough for all my guard.

It won't be a perfect match, but it will be 'close enough' in scale.
GWs stuff isn't designed to scale with any other producer's stuff (if you make it hard to use other people's stuff, then they have to buy your stuff.).

Y'know, the Osprey looks enough like a jet that all you need to do is leave off the props and you should be fine.

I was thinking that, but I was thinking that with the over sized Tau engines on it, it would look a little more in line with GW wonky design.