THE blockbuster musical Chitty Chitty Bang Bang opens at the Theatre Royal tonight for a phantasmagorical three-week summer run. And the term blockbuster is well-deserved. The show, which opens in Plymouth before a national tour, has a cast and crew of over 100 (including 10 dogs), sensational sets, a full orchestra and stunning special effects, including the magical flying car.

A hugely popular film with Dick Van Dyke and Sally Ann Howes, Chitty Chitty Bang Bang is the story of eccentric inventor Caractacus Potts, and his two children, Jemima and Jeremy. Together with Grandpa Potts and the lovely Truly Scrumptious they all try to outwit the dastardly Baron of Vulgaria and the evil childcatcher.

The original book was written by James Bond creator Ian Fleming and hit songs include Truly Scrumptious, Toot Sweets, Hushabye Mountain and the Oscar-nominated title song.

Actress Rachel Stanley, who plays Truly, is delighted to be back in Plymouth for the show – she regards it almost as a second home.

"My mum's sister lives in Peverell and I've been coming down to Plymouth every single summer since I was born," she says.

"So when I tour I go and stay with Auntie Betty. I stayed with her when I did White Christmas here and 42nd Street, which was my first job in the theatre."

Rachel toured with the last production of Chitty Chitty Bang Bang, which was only able to play in large venues. This production is every bit as spectacular but capable of playing in more normal-sized theatres, with sets and props built at the Theatre Royal's TR2 production centre.

"It's practically a new show," says Rachel. "It tells the story fantastically well and it's been interesting to see it done differently.

"But we still have the family dog, Edison, plus 10 other dogs. And lots of children.

"There's a lot of attention to detail. There's a haircutting machine which is absolutely fantastic, and a breakfast machine. It's marvellous."

Although Rachel gets to wear lots of "frothy pink" costumes, when she first meets Caractacus Potts (played by Darren Bennett) she arrives on a motorcycle in leathers, goggles and a cravat.

She comes from an upper-class family and her father owns the local sweet factory. She and Caractacus clash and argue over everything, but before long they fall in love – something the children are first to recognise.

For Rachel, who loved watching the film when she was growing up, the songs are memorable and merge beautifully with new music written for the show.

"Toot Sweets is probably everybody's favourite song, but the car is the real showstopper. I love it when Truly and Caractacus dress up as the doll and the puppet for the Baron. It's a great number.

"Whenever the musical came on TV I would just shut up and watch it.

"We are having the best time. This show attracts really lovely people. We are like a family, we're all thrown together. In America they call us 'gypsies' for the way we travel and work together.

"When I finished the last tour I really missed it – it was fun from beginning to end.

"It's just a wonderful show and I'm so happy to be back.

Chitty Chitty Bang Bang opens tonight and ends on Saturday, July 25. Tickets are £10-£40.50 and there are two matinees a week. Box office: 01752 267222.