Blog

At Hartzell Propeller, we’re constantly inspired by the passion and dedication of the kitplane community. That’s why we’re excited to collaborate with Carson Stilson (@Wairworthy), who has documented his entire aircraft homebuilding journey from start to finish.

Carson is a Utah-based private pilot, aircraft kitbuilder, content creator, and founder of the aviation-focused apparel company, Wairworthy. He recently completed his Zenith STOL CH 750 Super Duty, equipped with the backcountry-ready Trailblazer carbon fiber composite propeller.

We sat down with Carson to learn about his background, his kitplane building experience, and why the Trailblazer was the best propeller choice for his mission.

Enjoy the full Q&A below:

Tell us about your background and path to becoming a pilot. Who or what inspired you to want to become a pilot?

I grew up inspired by aviation. I spent far too many hours as a kid building airplanes with Legos, flying in Flight Simulator on the computer, and simply wanting to fly the real thing.

My dad bought a Cessna 172 when I was in high school, and I was able to get my first 10 flight hours in that airplane. I worked at my local airport cleaning airplanes, but unfortunately, I didn’t make nearly enough to justify paying for fuel to fly. Because of that, I took a break from flying until 2020, when I finally had enough income to finish my Private Pilot Certificate.

There was never an “ah-ha” moment with aviation. I’ve just loved airplanes for as long as I can remember.

You’re the founder of Wairworthy, an aviation bag and apparel brand. How did the idea for Wairworthy come about?

Like many pilots, as I worked on my pilot certificate, I wanted to get all the associated equipment: logbooks, headset, EFB, and, of course, a flight bag to carry everything.

As I searched for a flight bag, I couldn’t find anything sleek or modern that fit the style I liked. Everything gave off a bit of a cheap vibe, and I ended up buying a higher-quality non-aviation bag. It was a premium bag but completely missing features a pilot might want, such as a dedicated headset space. I saw a huge void in the market for a premium flight bag and decided to make my own.

I made my career in marketing and product development, so it was a great opportunity to turn my passion into a potential business. I came up with a premium design and launched a Kickstarter campaign that funded in about 15 minutes. That success allowed me to launch multiple flight bags, apparel, and accessories for pilots. It is what funds my addiction to building airplanes and making flying content.

You recently completed your aircraft build — congratulations! What drew you to build your own aircraft, and the Zenith STOL CH 750 Super Duty specifically?

Honestly, I never expected to build my own airplane in my 30s. After completing my pilot certificate, I purchased a quarter share of a Mooney M20J. It was a wonderful airplane, but I had spent so much of my training time watching backcountry aviation videos that I knew I eventually wanted a bush plane. The opportunity came up to buy into a Rans S20 Raven and I jumped on it.

I got my tailwheel endorsement in this airplane and experienced my first backcountry landings with it. It’s a great airplane, but after flying it for a while, I knew I wanted something more. I wanted an airplane that was completely custom to me, with even more backcountry performance. I wanted more than two seats, and I wanted to stop paying a ton for tailwheel insurance. I decided that the only way to achieve these things was to build my own airplane. After searching for a kit that fit my needs, I kept coming back to the Zenith STOL CH 750 Super Duty. The kit could be completed in 700 hours, and the ability to modify and customize the airplane is pretty much unmatched.

The Super Duty is an all-aluminum aircraft, and the holes are almost entirely match-hole drilled, which means a lot of the assembly is as simple as lining up holes and putting a rivet in. I had zero experience with metalworking, so an easy build process was very appealing. The kit was great, but the performance was what really sold me. With the ability to take off and land in less than 150 feet, I was sold.

Things only got better when my aircraft started outperforming the reported specifications on Zenith’s marketing sheet.

You shared so much of your kit-building journey on social media — the challenges and the milestones. What inspired you to share that process so openly, and what kind of response did you get from the aviation community?

I didn’t go into the build thinking I was going to document the entire thing. When I showed up to the Zenith Rudder Workshop in Missouri, I decided to make a short video showing what I was doing. That video exploded with interest. As the kit was about to arrive in St. George, I posted another video and my Instagram account went from 30,000 followers to over 115,000 in three days.

The excitement for my build was incredible. I decided it was worth the effort to document as much as possible and share it online, even if I knew it would add hundreds of hours to the build.

150 million views and 1.2 million followers later, it is now the most viewed kitplane build series ever. I don’t regret a single thing.

Your aircraft is equipped with a Hartzell Trailblazer carbon fiber composite propeller. What factors went into your propeller decision? Why was the propeller choice important to you as a kitbuilder and backcountry pilot?

My airplane is powered by a 215 hp Lycoming IO-390. An engine that large needs a propeller that can take advantage of that power. I also needed something light and easy to maintain. The carbon fiber Trailblazer was the perfect choice for my needs.

Having the constant speed gives me so much more speed than other Super Duties are seeing. I can easily hit 125 mph indicated. Most Super Duties are cruising at 105. Even with the added weight of the larger engine, I am still taking off in less than 150 feet, which is incredible.

I believe the Trailblazer is really making my engine shine. Landing and taking off that short means I spend a lot of my time in the backcountry. It’s not uncommon to end up with rock chips and scratches on your prop. Hartzell has an affordable kit that allows me to make repairs quickly. It makes the prop feel as good as new, and I don’t have to spend a bunch of money sending it in.

What were your first impressions flying the Trailblazer compared to other props you’ve used in the past?

It’s hard for me to compare. Most of my airplanes have had Hartzell propellers, and they have all performed great. I’ve never had a backcountry aircraft as powerful as my Zenith. Every time I take off, I’ve got a smile on my face because of how great it performs. The only real comparison I can go off of is from other Super Duty builders, and my performance is among the highest.

Now that you’ve accumulated more flight hours with your aircraft, has anything surprised you about the performance, look, or feel of the prop? What difference has it made in your overall flying experience?

I was originally warned to go with a lighter fixed-pitch propeller for my airplane because of the heavier nose. I went with the Hartzell anyway because I wanted the benefits of a constant speed. The payoff has been absolutely worth it.

In fact, I am not sure I would be getting off the ground any faster with a fixed-pitch, yet I know for a fact that my top-end speed is much higher. This is incredibly convenient when I need to fly a few hundred miles to a backcountry spot I want to explore. It can easily cut 30 to 40 minutes off my flight time, which gives me longer range and therefore a much larger area I can explore.

What advice would you give to someone dreaming of building their own aircraft?

If you have the time and the money, do it. Kits are dramatically improving, which results in safer aircraft, a huge reduction in build time, and a far better final product. With MOSAIC, we have so much to look forward to when it comes to experimental aviation. Just do your research, find the kit that fits your mission, and be ready to work.

What have been some of your favorite destinations or flying experiences so far? Are there any places you’re still hoping to explore?

I love exploring the backcountry, and there are hundreds of strips in Utah that I am looking forward to visiting now that my plane is finished. I really love the Ibex lakebed. I love flying to Sedona for lunch. Grand Gulch Mine in Arizona is also a really unique spot. If I can explore or fill my stomach while I am there, I will usually like just about any landing spot.

What’s next for you? Any big goals or projects on the horizon?

I’ve built the most expensive Zenith aircraft ever. Now I want to try building the lowest cost, yet still safe and capable, aircraft I can. I’m looking forward to sharing what I have in mind next year.

Aside from building, I plan to fly the daylights out of my airplane. I’ve put 100 hours on it in three months, and I don’t plan to slow down. Here’s to thousands more.

Find the Perfect Prop for Your Project Plane

For more insights into Carson’s kitplane journey, check out his videos on YouTube, Instagram, or TikTok.

To learn more about the Trailblazer propeller or any of our kitplane propeller options, reach out to our team. We’d be happy to help you find the right aircraft propeller that fits your flying mission and performance goals.

P.S. Love backcountry flying? You should know that Hartzell Propeller is offering a $1,000 discount on new Hartzell backcountry aircraft propellers for members of the Recreational Aviation Foundation (RAF) through the end of 2025.

For each discounted propeller sold, Hartzell will donate $250 to support the RAF’s mission of preserving backcountry aviation access. Hartzell backcountry propellers eligible for the discount include the Trailblazer, the Pathfinder, and the Carbon Voyager. To learn more, drop us a line!