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Pilot to Pilot · Thursday · 39 min

I Threw Away Half My Airplane: Building a Zenith Kit Plane with Carson Stilson

Carson Stilson built his own Zenith Super Duty kit plane in two and a half years and about 1,200 hours, then flew it to Oshkosh. He shares what building an experimental aircraft really takes. Carson never planned to build an airplane in his thirties. He did it anyway, while working full time and raising two young kids. He explains why he chose a Zenith over a tailwheel kit, why he did most of the build himself, and how he kept going through the slow stretches. One of those stretches came a few weeks in, when he accidentally threw away half his airplane's skins. In this episode: Why Carson chose a Zenith: STOL performance, cost, and no ground-loop worries How the Zenith rudder workshop led him to buy the kit Builder Assist vs. building it yourself, and when to get help with the engine and avionics "90% done, 90% to go": wiring, final assembly, and the last six months Putting a Lycoming IO-390 on a Super Duty for high-density-altitude backcountry flying in Utah The DAR inspection, the first flight on July 4th, and flying to EAA AirVenture Oshkosh Why experimental and kit aircraft, along with MOSAIC, could be the future of personal aviation Carson's dream fleet: a bush plane, a 200-knot family hauler, and a show plane Thinking about building a kit plane? Send this to the friend who keeps saying "someday." Pilot to Pilot Magazine Get your copy at https://pilottopilothq.com/mag Our Sponsors Please support the companies that support the show. Aero Tow: The Aero Tow T2 moves tail draggers and medium twins up to 15,000 lbs. Pilot to Pilot listeners get $100 off with promo code PILOT100 at https://amigoaerotow.com Textron Aviation: Owner support from the people who built your aircraft. Learn more at https://txtav.com Avemco Insurance: Pilot to Pilot listeners save 5%. Call (888) 635-4297 or visit: Aircraft owners: https://avemco.com/4297-owner Non-owners: https://avemco.com/4297-non-owner Garmin: Plan, file, fly, and log with the Garmin Pilot app. Allworth Airline Advisors: Watch "The Hot Seat," an on-demand webinar where airline benefits experts answer pilots' open enrollment questions. Register at https://allworthairline.com/justin

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Carson Stilson built his own Zenith Super Duty kit plane in two and a half years and about 1,200 hours, then flew it to Oshkosh. He shares what building an experimental aircraft really takes.

Carson never planned to build an airplane in his thirties. He did it anyway, while working full time and raising two young kids. He explains why he chose a Zenith over a tailwheel kit, why he did most of the build himself, and how he kept going through the slow stretches. One of those stretches came a few weeks in, when he accidentally threw away half his airplane's skins.

In this episode:

  • Why Carson chose a Zenith: STOL performance, cost, and no ground-loop worries
  • How the Zenith rudder workshop led him to buy the kit
  • Builder Assist vs. building it yourself, and when to get help with the engine and avionics
  • "90% done, 90% to go": wiring, final assembly, and the last six months
  • Putting a Lycoming IO-390 on a Super Duty for high-density-altitude backcountry flying in Utah
  • The DAR inspection, the first flight on July 4th, and flying to EAA AirVenture Oshkosh
  • Why experimental and kit aircraft, along with MOSAIC, could be the future of personal aviation
  • Carson's dream fleet: a bush plane, a 200-knot family hauler, and a show plane

Thinking about building a kit plane? Send this to the friend who keeps saying "someday."


Pilot to Pilot Magazine
Get your copy at https://pilottopilothq.com/mag

Our Sponsors
Please support the companies that support the show.

Aero Tow: The Aero Tow T2 moves tail draggers and medium twins up to 15,000 lbs. Pilot to Pilot listeners get $100 off with promo code PILOT100 at https://amigoaerotow.com

Textron Aviation: Owner support from the people who built your aircraft. Learn more at https://txtav.com

Avemco Insurance: Pilot to Pilot listeners save 5%. Call (888) 635-4297 or visit:
Aircraft owners: https://avemco.com/4297-owner
Non-owners: https://avemco.com/4297-non-owner

Garmin: Plan, file, fly, and log with the Garmin Pilot app.

Allworth Airline Advisors: Watch "The Hot Seat," an on-demand webinar where airline benefits experts answer pilots' open enrollment questions. Register at https://allworthairline.com/justin



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