Building a Zenith Kit Plane: 1,200 Hours, One Big Mistake and a Flight to Oshkosh
Two and a half years, about 1,200 hours and half the airplane’s skins accidentally thrown away. How Carson Stilson built his Zenith and flew it to Oshkosh.
Carson Stilson never planned to build an airplane in his thirties. But over about two and a half years and roughly 1,200 hours, while working full time and raising two young kids, he built a Zenith Super Duty and flew it to EAA AirVenture Oshkosh.
In Episode 372, he walks Justin through what building an experimental airplane really involves.
- 01Why he chose a Zenith over a tailwheel kit
- 02Builder Assist vs building it all yourself
- 03Staying motivated through the slow middle of a build
- 04The “90% done, 90% to go” final stretch
- 05Choosing a Lycoming IO-390 for high-density-altitude flying
- 06The DAR inspection, first flight and the trip to Oshkosh
Choosing the kit
Carson chose a Zenith for short-field performance, cost and not having to worry about ground loops, compared with a tailwheel kit. A Zenith rudder workshop sealed the decision.
Doing it yourself, with help
He did most of the build himself and explains Builder Assist versus doing it all on your own, and when it makes sense to get help with the engine and avionics.
Throwing away half an airplane
A few weeks in, he accidentally threw away half of the airplane’s skins. He talks about staying motivated through mistakes and slow stretches, and the “90% done, 90% to go” phase of wiring and final assembly.
Engine, inspection and Oshkosh
He installed a Lycoming IO-390 for high-density-altitude backcountry flying in Utah. Then came the DAR inspection, a first flight on July 4th and the flight to Oshkosh.
The future of personal aviation
Carson explains why experimental and kit aircraft, along with MOSAIC, could shape personal aviation, and shares his dream fleet: a bush plane, a 200-knot family hauler and a show plane.
Carson Stilson
Carson Stilson built his own Zenith Super Duty kit plane in about 1,200 hours while working full time and raising two young children, then flew it to EAA AirVenture Oshkosh.
Frequently asked questions
How long does it take to build a Zenith kit plane?
Carson Stilson built his Zenith Super Duty in about 1,200 hours over roughly two and a half years.
What engine is in Carson’s Zenith Super Duty?
A Lycoming IO-390, chosen for high-density-altitude backcountry flying in Utah.
What is Builder Assist?
It is a program where builders get hands-on help completing parts of a kit. Carson compares it with building everything yourself in this episode.
