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These are the user uploaded subtitles that are being translated: 1 00:00:03,804 --> 00:00:06,038 Man: Right on this side here! 2 00:00:06,040 --> 00:00:08,574 Narrator: This elite team of engineers 3 00:00:08,576 --> 00:00:11,610 Is embarking on an epic endeavor. 4 00:00:11,612 --> 00:00:13,679 -Go down. -All good? 5 00:00:13,681 --> 00:00:17,583 They're attempting to build the longest, tallest, 6 00:00:17,585 --> 00:00:21,286 And fastest dive roller coaster in the world. 7 00:00:21,288 --> 00:00:23,722 This is not going to be a straightforward build. 8 00:00:23,724 --> 00:00:25,457 It's like a puzzle. 9 00:00:25,459 --> 00:00:29,294 I liken it to building a ship inside a bottle. 10 00:00:29,296 --> 00:00:33,732 Narrator: Constructed from more than 1,500 tons of steel, 11 00:00:33,734 --> 00:00:36,435 They are pushing to complete this ambitious build 12 00:00:36,437 --> 00:00:38,804 In just 16 months. 13 00:00:38,806 --> 00:00:40,339 The park is going to open on opening day, 14 00:00:40,341 --> 00:00:43,175 And we need to be ready. 15 00:00:43,177 --> 00:00:46,078 Narrator: To construct this record-breaking giant, 16 00:00:46,080 --> 00:00:49,615 The team must battle extreme cold... 17 00:00:49,617 --> 00:00:52,918 Temperature is down to minus-40 with your windchill. 18 00:00:52,920 --> 00:00:54,253 Very windy. 19 00:00:54,255 --> 00:00:56,555 It's something that we got to fight with. 20 00:00:56,557 --> 00:00:58,791 Narrator: ...And terrifying heights. 21 00:00:58,793 --> 00:01:01,460 Baptiste: You got to be on your game when you're up there. 22 00:01:01,462 --> 00:01:04,663 You got everybody's lives in your hands. 23 00:01:06,901 --> 00:01:10,536 Narrator: This colossal coaster ranks in a league of ambitious 24 00:01:10,538 --> 00:01:13,472 New engineering wonders 25 00:01:13,474 --> 00:01:17,176 That are bigger, faster, taller, 26 00:01:17,178 --> 00:01:21,513 And more advanced than anything ever constructed before. 27 00:01:21,515 --> 00:01:25,484 This is the inside story of the extraordinary challenge 28 00:01:25,486 --> 00:01:28,020 Of building these giants. 29 00:01:28,022 --> 00:01:30,989 -- Captions by vitac -- www.Vitac.Com 30 00:01:30,991 --> 00:01:33,992 Captions paid for by discovery communications 31 00:01:33,994 --> 00:01:39,965 ♪ 32 00:01:39,967 --> 00:01:43,435 Toronto, canada -- 33 00:01:43,437 --> 00:01:48,941 Home to the country's biggest and most popular theme park. 34 00:01:48,943 --> 00:01:53,278 Every year, over 3.5 million thrill seekers flock here 35 00:01:53,280 --> 00:01:59,451 To experience the fastest, biggest, and scariest rides. 36 00:01:59,453 --> 00:02:00,786 You never know what's coming next. 37 00:02:00,788 --> 00:02:03,021 The adrenaline is probably the best part -- 38 00:02:03,023 --> 00:02:05,591 The speed, the drops, the twists and turns. 39 00:02:05,593 --> 00:02:07,192 I just want to be scared. 40 00:02:07,194 --> 00:02:11,163 ♪ 41 00:02:11,165 --> 00:02:14,500 Narrator: As roller coaster technology soars to new heights, 42 00:02:14,502 --> 00:02:17,202 It's a huge challenge for director of construction 43 00:02:17,204 --> 00:02:21,540 Peter switzer to keep this park ahead of the curve. 44 00:02:23,811 --> 00:02:26,512 My kids say that I've got the best job in the world. 45 00:02:26,514 --> 00:02:31,350 We get to build things where people get to come and have fun. 46 00:02:31,352 --> 00:02:34,486 We want to stay on the cutting edge of new attractions. 47 00:02:34,488 --> 00:02:36,455 We're ready to provide the next thrill. 48 00:02:39,960 --> 00:02:42,661 Narrator: Peter has called in swiss roller coaster design 49 00:02:42,663 --> 00:02:45,264 Specialists bolliger & mabillard 50 00:02:45,266 --> 00:02:48,867 To engineer a brand-new ride for the park -- 51 00:02:48,869 --> 00:02:54,706 A dive coaster featuring a sheer 90-degree vertical drop. 52 00:02:56,010 --> 00:02:57,876 Bolliger: It's like falling down a cliff, 53 00:02:57,878 --> 00:02:59,745 But not only falling down the cliff -- 54 00:02:59,747 --> 00:03:02,915 You are falling face-down, looking, you know, 55 00:03:02,917 --> 00:03:06,285 At 75 meters of emptiness. 56 00:03:06,287 --> 00:03:09,521 It's really scary. 57 00:03:09,523 --> 00:03:12,724 Narrator: Roller coasters used to need a forest of structural supports 58 00:03:12,726 --> 00:03:15,127 To hold them steady. 59 00:03:15,129 --> 00:03:17,896 Today, designers use computer models 60 00:03:17,898 --> 00:03:20,399 To precision engineer elegant 61 00:03:20,401 --> 00:03:24,403 But strong self-supporting structures. 62 00:03:24,405 --> 00:03:27,606 When we design a coaster, we really want the guests 63 00:03:27,608 --> 00:03:29,508 To have a great experience 64 00:03:29,510 --> 00:03:34,046 And to want to ride the coaster again and again. 65 00:03:34,048 --> 00:03:37,282 Narrator: After a year of detailed design work, 66 00:03:37,284 --> 00:03:41,019 This swiss team has pulled out all the stops to devise 67 00:03:41,021 --> 00:03:44,823 A world-record-smashing dive coaster. 68 00:03:44,825 --> 00:03:48,293 It's called the yukon striker. 69 00:03:48,295 --> 00:03:50,762 Bolliger: It will have the longest drop. 70 00:03:50,764 --> 00:03:52,898 It will be the fastest, the longest, 71 00:03:52,900 --> 00:03:56,335 And it'll have the most inversions on dive coaster. 72 00:03:59,139 --> 00:04:00,806 Narrator: Towering above the city, 73 00:04:00,808 --> 00:04:06,478 The yukon striker will be a coaster like no other. 74 00:04:06,480 --> 00:04:08,814 Powerful winches lift its riders 75 00:04:08,816 --> 00:04:13,418 Up a giant 223-foot-high lift hill 76 00:04:13,420 --> 00:04:16,655 Before its unique 24-seater cars 77 00:04:16,657 --> 00:04:19,658 Built without floors 78 00:04:19,660 --> 00:04:24,429 Plunge over the 90-degree vertical drop, 79 00:04:24,431 --> 00:04:27,366 Accelerating to 81 miles per hour. 80 00:04:30,104 --> 00:04:33,905 More than 1,500 tons of precision steel 81 00:04:33,907 --> 00:04:38,010 Make up over half a mile of winding track. 82 00:04:38,012 --> 00:04:41,980 With more upside-down sections than any other dive coaster 83 00:04:41,982 --> 00:04:45,150 And the first full loop-the-loop, 84 00:04:45,152 --> 00:04:47,319 It will be the ultimate thrill. 85 00:04:47,321 --> 00:04:51,957 ♪ 86 00:04:51,959 --> 00:04:53,692 For peter's team at the park, 87 00:04:53,694 --> 00:04:58,897 Constructing this giant will be a monumental challenge. 88 00:04:58,899 --> 00:05:01,867 Switzer: This is not going to be a straightforward build. 89 00:05:01,869 --> 00:05:06,104 It's got so many twists and turns and changes in direction. 90 00:05:06,106 --> 00:05:08,273 It's like a puzzle. 91 00:05:08,275 --> 00:05:09,741 Narrator: To add to the pressure, 92 00:05:09,743 --> 00:05:12,611 The team must build most of this colossal coaster 93 00:05:12,613 --> 00:05:18,283 While the park is closed during the depths of winter. 94 00:05:18,285 --> 00:05:20,252 This winter, we're expecting bitterly cold temperatures 95 00:05:20,254 --> 00:05:22,154 Down into the minus-30s. 96 00:05:22,156 --> 00:05:23,422 We're gonna have to deal with what we get 97 00:05:23,424 --> 00:05:25,190 Because the park is going to open on opening day, 98 00:05:25,192 --> 00:05:27,859 And we need to be ready. 99 00:05:27,861 --> 00:05:29,628 Narrator: This is how they'll do it. 100 00:05:32,800 --> 00:05:38,270 Workers precision-build the steel track in sections offsite. 101 00:05:38,272 --> 00:05:41,740 At the park, engineers bolt several pieces together 102 00:05:41,742 --> 00:05:45,777 On the ground, lift them into position, 103 00:05:45,779 --> 00:05:49,981 Then support them with super-strong steel columns. 104 00:05:49,983 --> 00:05:52,117 Work moves methodically round the circuit 105 00:05:52,119 --> 00:05:56,521 From start to finish until the track is complete. 106 00:05:56,523 --> 00:06:00,225 Next, engineers install a 700-foot chain 107 00:06:00,227 --> 00:06:07,532 And powerful motor to haul the cars 223 feet into the sky. 108 00:06:07,534 --> 00:06:11,603 Finally, they fit and test the track-side braking systems 109 00:06:11,605 --> 00:06:16,375 That allow them to safely run three sets of cars at once, 110 00:06:16,377 --> 00:06:21,513 Taking 12,000 thrill seekers a day on the ride of a lifetime. 111 00:06:21,515 --> 00:06:26,017 ♪ 112 00:06:26,019 --> 00:06:28,787 It's early morning at the park. 113 00:06:28,789 --> 00:06:31,456 Man: Hey. Coming up. 114 00:06:31,458 --> 00:06:33,225 With the doors now closed to the public 115 00:06:33,227 --> 00:06:36,795 For the winter season, workers race to unload 116 00:06:36,797 --> 00:06:41,466 The first prefabricated pieces of the new coaster. 117 00:06:41,468 --> 00:06:42,901 Switzer: Yeah, it's quite complicated. 118 00:06:42,903 --> 00:06:44,669 There's hundreds and hundreds of pieces. 119 00:06:44,671 --> 00:06:47,239 Straighten it out a bit. 120 00:06:47,241 --> 00:06:50,375 Narrator: The team's first task is to transport the steel 121 00:06:50,377 --> 00:06:53,044 Through the park to the build site. 122 00:06:55,416 --> 00:06:58,550 Where trucks won't fit, they must use cranes 123 00:06:58,552 --> 00:07:03,422 To leapfrog the pieces over existing rides. 124 00:07:03,424 --> 00:07:06,525 Switzer: I liken it to building a ship inside a bottle. 125 00:07:06,527 --> 00:07:08,960 You're limited within that bottle with what you can do 126 00:07:08,962 --> 00:07:13,231 And where you can reach and where you can place things. 127 00:07:13,233 --> 00:07:18,470 Narrator: Despite the difficult site, they make good progress. 128 00:07:18,472 --> 00:07:20,539 It takes just nine weeks for workers 129 00:07:20,541 --> 00:07:21,807 To install the framework 130 00:07:21,809 --> 00:07:25,977 For the giant lift hill and vertical drop. 131 00:07:25,979 --> 00:07:31,082 ♪ 132 00:07:31,084 --> 00:07:35,654 Now the team faces its first real challenge -- 133 00:07:35,656 --> 00:07:37,622 A tricky track section masterminded 134 00:07:37,624 --> 00:07:43,795 By the swiss designers called the immelmann turn. 135 00:07:43,797 --> 00:07:45,497 The track at the top of the immelmann 136 00:07:45,499 --> 00:07:48,967 Will rise 160 feet above the ground. 137 00:07:48,969 --> 00:07:51,303 It will have very few supports. 138 00:07:53,373 --> 00:07:57,909 For the team on-site, assembling it won't be easy. 139 00:07:57,911 --> 00:08:00,111 'cause of the size and shape and how big it is, 140 00:08:00,113 --> 00:08:03,315 It's gonna be a big challenge for the men putting it together. 141 00:08:03,317 --> 00:08:07,986 ♪ 142 00:08:07,988 --> 00:08:11,523 Narrator: First, workers will lift a small support column 143 00:08:11,525 --> 00:08:17,329 Bolted to its base and haul in a track using a second crane. 144 00:08:17,331 --> 00:08:21,266 Next, they lift a much larger support column in sections 145 00:08:21,268 --> 00:08:24,803 And tie it of with guylines. 146 00:08:24,805 --> 00:08:27,706 Cranes then lift in two pre-joined 147 00:08:27,708 --> 00:08:29,674 Double lengths of track. 148 00:08:29,676 --> 00:08:34,880 Each piece is 60 feet long and weighs over 20 tons. 149 00:08:34,882 --> 00:08:39,084 They must get the rotation of each twisting piece just right 150 00:08:39,086 --> 00:08:45,590 So ironworkers can line them up and bolt them together by hand. 151 00:08:45,592 --> 00:08:47,859 The two cranes must hold the track steady 152 00:08:47,861 --> 00:08:50,495 Until every piece is secure. 153 00:08:50,497 --> 00:08:53,431 Only then can the loop support itself. 154 00:08:57,004 --> 00:09:00,805 Switzer: We don't want the men to have to make changes up in the air. 155 00:09:00,807 --> 00:09:02,807 The pieces need to fit together, and if they don't, 156 00:09:02,809 --> 00:09:07,612 Then we'll have to lay them down and come up with another plan. 157 00:09:07,614 --> 00:09:12,717 Narrator: In charge of assembling the immelmann is foreman bill woods. 158 00:09:12,719 --> 00:09:15,487 We're setting up a lot of cranes this morning. 159 00:09:15,489 --> 00:09:17,255 There's a lot going on -- a lot of congestion, 160 00:09:17,257 --> 00:09:19,157 A lot of movement, a lot of people. 161 00:09:23,297 --> 00:09:25,063 Narrator: The first crane takes the weight 162 00:09:25,065 --> 00:09:27,766 Of the 75-foot-long column legs... 163 00:09:27,768 --> 00:09:30,468 Woods: We ought to be able to put them down easier, too. 164 00:09:30,470 --> 00:09:32,504 ...And hoists them into the air. 165 00:09:36,710 --> 00:09:38,710 Alright, you're there. Hold that. 166 00:09:40,314 --> 00:09:43,648 Once the leg is vertical, the team must line up its feet 167 00:09:43,650 --> 00:09:46,551 With the anchor bolts on the ground... 168 00:09:46,553 --> 00:09:49,154 Keep going, nice and easy. 169 00:09:49,156 --> 00:09:51,556 ...But they've run into an alignment issue. 170 00:09:51,558 --> 00:09:54,759 Let's give that a wiggle. 171 00:09:54,761 --> 00:09:57,429 The holes at the base of the column don't line up 172 00:09:57,431 --> 00:10:00,398 With the foundation bolts, 173 00:10:00,400 --> 00:10:04,269 Leaving the leg hanging precariously from the crane. 174 00:10:19,419 --> 00:10:25,290 ♪ 175 00:10:25,292 --> 00:10:28,426 Narrator: At canada's most popular theme park, 176 00:10:28,428 --> 00:10:30,895 A team of engineers and ironworkers 177 00:10:30,897 --> 00:10:35,066 Is racing to construct the world's biggest dive coaster 178 00:10:35,068 --> 00:10:38,536 Featuring a sheer 90-degree vertical drop. 179 00:10:40,941 --> 00:10:45,710 But a 75-foot-tall supporting column won't fit on its base. 180 00:10:45,712 --> 00:10:46,878 So we need to know what's wrong. 181 00:10:46,880 --> 00:10:48,346 What's wrong, yeah, that's right. 182 00:10:48,348 --> 00:10:50,248 Woods: Everything -- this is such a tight tolerance, 183 00:10:50,250 --> 00:10:51,950 Right down to the millimeter, 184 00:10:51,952 --> 00:10:55,320 And, yeah, we're talking, like, here, over 30, 40 mils out. 185 00:10:55,322 --> 00:11:00,458 ♪ 186 00:11:00,460 --> 00:11:05,030 Narrator: The solution calls for drastic measures. 187 00:11:05,032 --> 00:11:08,066 They use a powerful oxy-acetylene torch 188 00:11:08,068 --> 00:11:11,736 To cut through the 1.5-inch-thick steel base plate 189 00:11:11,738 --> 00:11:13,405 To make the holes bigger. 190 00:11:13,407 --> 00:11:18,443 ♪ 191 00:11:18,445 --> 00:11:20,779 Switzer: The baseplate was off by 5.5 degrees. 192 00:11:20,781 --> 00:11:24,049 We were able to accommodate that 5.5-degree discrepancy 193 00:11:24,051 --> 00:11:25,650 By elongating the holes, 194 00:11:25,652 --> 00:11:27,452 And there's no future issues 195 00:11:27,454 --> 00:11:29,854 Regarding the integrity of that connection. 196 00:11:31,858 --> 00:11:33,491 Coming up on your line. 197 00:11:35,729 --> 00:11:39,664 Narrator: They quickly slot the modified column into place. 198 00:11:39,666 --> 00:11:42,233 Glad it came together. Column's erected. 199 00:11:43,970 --> 00:11:46,905 Next up -- the first piece of track. 200 00:11:46,907 --> 00:11:48,506 Keep on coming up. 201 00:11:48,508 --> 00:11:52,610 ♪ 202 00:11:52,612 --> 00:11:54,245 Almost there, hold that. 203 00:11:57,050 --> 00:11:59,884 Now for the top of the immelmann. 204 00:11:59,886 --> 00:12:01,986 Yeah, just like that. 205 00:12:01,988 --> 00:12:05,123 They must align two twisting double lengths of track 206 00:12:05,125 --> 00:12:10,395 Perfectly so workers up high can insert their bolts. 207 00:12:10,397 --> 00:12:12,430 The two cranes can't let go 208 00:12:12,432 --> 00:12:15,667 Until every connection is secure. 209 00:12:15,669 --> 00:12:17,736 Woods: We've got a lot to do. 210 00:12:17,738 --> 00:12:23,408 Narrator: The team must complete this complex section in a single day. 211 00:12:23,410 --> 00:12:26,878 If they don't, they'll have to set everything back down 212 00:12:26,880 --> 00:12:30,115 And start from the beginning tomorrow. 213 00:12:30,117 --> 00:12:33,051 It would be a costly delay. 214 00:12:33,053 --> 00:12:36,421 Woods: We got to have all of these items installed today. 215 00:12:36,423 --> 00:12:38,156 Yeah, hopefully we don't get into the nighttime here 216 00:12:38,158 --> 00:12:39,591 So we can see each other. 217 00:12:39,593 --> 00:12:41,526 Let's get the 200 up. 218 00:12:41,528 --> 00:12:44,062 Yep, keep on coming up, buddy. Nice and easy. 219 00:12:44,064 --> 00:12:49,167 Ironworker kyle baptiste is responsible for the track. 220 00:12:49,169 --> 00:12:51,035 80% of the work is done on the ground here 221 00:12:51,037 --> 00:12:52,937 Just to get the thing right. 222 00:12:52,939 --> 00:12:54,839 Coming up on the 200. 223 00:12:54,841 --> 00:12:57,976 Narrator: They use a complex rig of chains to rotate the track 224 00:12:57,978 --> 00:13:01,880 To the right orientation at ground level. 225 00:13:01,882 --> 00:13:03,314 Baptiste: This is a bit tricky, 226 00:13:03,316 --> 00:13:04,549 'cause you can't just slam these pieces together. 227 00:13:04,551 --> 00:13:07,652 You got to have them perfectly flush. 228 00:13:07,654 --> 00:13:09,654 That one's gonna be tricky to rig up 229 00:13:09,656 --> 00:13:12,924 'cause, like I say, it's just a corkscrew that thing. 230 00:13:15,061 --> 00:13:19,497 Narrator: They lift the first piece 130 feet high into the air. 231 00:13:19,499 --> 00:13:20,765 Keep on going. 232 00:13:20,767 --> 00:13:23,968 You got another 10 or more feet to go. 233 00:13:23,970 --> 00:13:25,804 With the weather deteriorating, 234 00:13:25,806 --> 00:13:29,374 Kyle follows it up in the bucket lift. 235 00:13:29,376 --> 00:13:32,911 Do you want to start getting us close to that connection? 236 00:13:32,913 --> 00:13:35,513 The angle is just right. 237 00:13:35,515 --> 00:13:38,716 You got that guy. 238 00:13:38,718 --> 00:13:40,652 But bolting one end... 239 00:13:40,654 --> 00:13:41,920 Yeah, we'll get it. We'll get it. 240 00:13:41,922 --> 00:13:43,621 ...Isn't enough to hold it up. 241 00:13:45,959 --> 00:13:47,625 The crane must keep hold of it 242 00:13:47,627 --> 00:13:51,529 While they lift the next piece of track into place. 243 00:13:51,531 --> 00:13:54,165 Switzer: Everything's done slow and methodically. 244 00:13:54,167 --> 00:13:57,669 The columns won't support themselves without the track, 245 00:13:57,671 --> 00:13:59,704 And the track won't support itself without the column, 246 00:13:59,706 --> 00:14:01,773 So those two pieces need to come together 247 00:14:01,775 --> 00:14:04,309 Much like a house of cards holds itself together. 248 00:14:07,280 --> 00:14:08,880 Narrator: 7:00 p.M. 249 00:14:10,851 --> 00:14:12,684 I.R. To 200. 250 00:14:14,855 --> 00:14:16,921 Baptiste: Once you start something, you got to finish it. 251 00:14:16,923 --> 00:14:20,391 You can't just shut everything down for the night. 252 00:14:20,393 --> 00:14:24,262 Narrator: They're losing light, making this task even tougher. 253 00:14:24,264 --> 00:14:25,897 Coming up on your line. 254 00:14:25,899 --> 00:14:28,199 You know you got everybody's lives 255 00:14:28,201 --> 00:14:30,969 When they're riding this thing in your hands. 256 00:14:30,971 --> 00:14:34,339 This thing has to be perfect. It has to be tight. 257 00:14:34,341 --> 00:14:35,974 You have to get it right. 258 00:14:35,976 --> 00:14:39,177 You have to. 259 00:14:39,179 --> 00:14:40,812 We have a bit more. 260 00:14:44,684 --> 00:14:47,151 More, sling to the left. 261 00:14:47,153 --> 00:14:48,786 Okay, hold that. 262 00:14:50,957 --> 00:14:53,992 Narrator: It takes six hours of painstaking work 263 00:14:53,994 --> 00:14:57,862 For kyle's team to tie the two sections together 264 00:14:57,864 --> 00:15:00,765 So the cranes can finally let go. 265 00:15:00,767 --> 00:15:08,606 ♪ 266 00:15:08,608 --> 00:15:11,409 The following morning, with the immelmann complete, 267 00:15:11,411 --> 00:15:14,412 The coaster build ramps up. 268 00:15:14,414 --> 00:15:17,715 The team needs a constant supply of track. 269 00:15:17,717 --> 00:15:19,150 Alright, buddy, boom 'er up. 270 00:15:19,152 --> 00:15:21,552 ...And building a structure like this requires 271 00:15:21,554 --> 00:15:24,789 Every single piece to be millimeter accurate. 272 00:15:24,791 --> 00:15:28,927 ♪ 273 00:15:28,929 --> 00:15:31,796 Every inch of coaster starts life here 274 00:15:31,798 --> 00:15:36,467 At vast steel fabricators over the border in batavia, ohio. 275 00:15:39,439 --> 00:15:43,107 Bob mampe is in charge. 276 00:15:43,109 --> 00:15:46,077 There's never a normal day in this factory. 277 00:15:46,079 --> 00:15:50,481 We have 95 folks building roller coasters. 278 00:15:50,483 --> 00:15:53,151 Narrator: This is how they turn raw steel 279 00:15:53,153 --> 00:15:55,453 Into precision-engineered track. 280 00:15:55,455 --> 00:16:00,258 ♪ 281 00:16:00,260 --> 00:16:02,060 At the heart of each section, 282 00:16:02,062 --> 00:16:04,395 They weld a series of rigid boxes together 283 00:16:04,397 --> 00:16:09,834 Out of high-tensile steel, giving it incredible strength. 284 00:16:09,836 --> 00:16:13,538 Steel plates called ribs 285 00:16:13,540 --> 00:16:15,873 Support the two six-inch-thick rails 286 00:16:15,875 --> 00:16:19,177 On which the coaster will run. 287 00:16:19,179 --> 00:16:22,246 The distance between the rails must be perfect 288 00:16:22,248 --> 00:16:25,116 Or the train will wobble from side to side, 289 00:16:25,118 --> 00:16:29,754 Giving passengers a harsh, bumpy ride. 290 00:16:29,756 --> 00:16:31,723 At the end of each track section, 291 00:16:31,725 --> 00:16:35,360 They place special plates with pre-drilled holes. 292 00:16:35,362 --> 00:16:39,063 These must line up exactly with the next piece of track 293 00:16:39,065 --> 00:16:41,833 To create a perfectly smooth ride. 294 00:16:41,835 --> 00:16:45,570 ♪ 295 00:16:45,572 --> 00:16:47,305 Mampe: It's as if you're flying in an airplane, 296 00:16:47,307 --> 00:16:50,375 If you have a nice smooth track that does all these incredible 297 00:16:50,377 --> 00:16:55,413 Aerobatic maneuvers, without turbulence. 298 00:16:55,415 --> 00:16:58,950 Narrator: Bob's team must ensure that every aspect of the track 299 00:16:58,952 --> 00:17:03,121 Is engineered exactly to the swiss designers' specifications. 300 00:17:07,360 --> 00:17:10,361 Plasma cutters precision carve steel plates 301 00:17:10,363 --> 00:17:14,732 At over 36,000 degrees fahrenheit. 302 00:17:14,734 --> 00:17:17,201 Man: It's a real precise machine, it cuts really good, 303 00:17:17,203 --> 00:17:18,936 And it has to for what we do. 304 00:17:21,808 --> 00:17:24,442 Sand blasters lift microscopic impurities 305 00:17:24,444 --> 00:17:26,411 Off every inch of rail. 306 00:17:30,917 --> 00:17:33,151 The most critical part is making sure 307 00:17:33,153 --> 00:17:35,520 That the distance between the two rails remains 308 00:17:35,522 --> 00:17:39,424 Constant across all sections of track 309 00:17:39,426 --> 00:17:43,394 To keep the ride silky smooth. 310 00:17:43,396 --> 00:17:46,697 Get it wrong, and it could cause major time delays 311 00:17:46,699 --> 00:17:49,767 And overages for the build team at the park. 312 00:18:01,448 --> 00:18:05,616 ♪ 313 00:18:05,618 --> 00:18:09,287 Narrator: In ohio, a team of specialized steel fabricators 314 00:18:09,289 --> 00:18:11,789 Is precision engineering track sections 315 00:18:11,791 --> 00:18:14,725 For the world's biggest dive roller coaster. 316 00:18:17,464 --> 00:18:23,668 It's vital that they keep the rails exactly 70.8 inches apart. 317 00:18:23,670 --> 00:18:24,802 You don't want to get beat up. 318 00:18:24,804 --> 00:18:25,937 You want to have a nice smooth ride, 319 00:18:25,939 --> 00:18:27,839 And that's what our goal is. 320 00:18:30,243 --> 00:18:33,344 Narrator: They use a set of rigid hydraulic handcuffs 321 00:18:33,346 --> 00:18:37,115 To position the rails to within a tenth of a millimeter, 322 00:18:37,117 --> 00:18:41,719 Then the welder fuses the steel together. 323 00:18:41,721 --> 00:18:43,121 Mampe: It's so important, too. 324 00:18:43,123 --> 00:18:47,191 You have these tolerances within tenths of millimeters. 325 00:18:47,193 --> 00:18:50,795 Narrator: They test-bolt every single piece of track to its neighbor 326 00:18:50,797 --> 00:18:53,397 To ensure they line up perfectly. 327 00:18:57,103 --> 00:19:00,538 Then they prime, paint, and custom-ship 328 00:19:00,540 --> 00:19:03,941 Each piece 400 miles to toronto. 329 00:19:03,943 --> 00:19:11,249 ♪ 330 00:19:11,251 --> 00:19:14,252 On-site, it takes the construction team 331 00:19:14,254 --> 00:19:17,355 12 weeks to assemble the first 80 pieces 332 00:19:17,357 --> 00:19:19,924 Of this gigantic jigsaw together. 333 00:19:22,095 --> 00:19:26,931 Around 3,000 feet of twisting steel is now firmly in place. 334 00:19:26,933 --> 00:19:36,007 ♪ 335 00:19:36,009 --> 00:19:40,411 But now the team faces a new challenge. 336 00:19:40,413 --> 00:19:43,381 As the yukon striker grows bigger, 337 00:19:43,383 --> 00:19:46,017 The completed sections of track make it difficult 338 00:19:46,019 --> 00:19:49,987 To squeeze their cranes into position. 339 00:19:49,989 --> 00:19:51,822 Switzer: Today we're in quite a congested portion 340 00:19:51,824 --> 00:19:52,924 Of our construction site. 341 00:19:52,926 --> 00:19:53,991 We're having to get quite creative 342 00:19:53,993 --> 00:19:56,827 With the positioning of the equipment. 343 00:19:56,829 --> 00:19:58,529 Narrator: With no other option, 344 00:19:58,531 --> 00:20:01,699 Peter and his team have taken a radical decision 345 00:20:01,701 --> 00:20:06,904 To finish building the coaster in a highly unorthodox way. 346 00:20:06,906 --> 00:20:08,706 Because we've got a congested site 347 00:20:08,708 --> 00:20:12,543 And we're limited with the amount of space that we have, 348 00:20:12,545 --> 00:20:14,779 We've decided to build out of sequence. 349 00:20:16,950 --> 00:20:19,383 Narrator: Ideally, the team would build the roller coaster 350 00:20:19,385 --> 00:20:22,853 In sequence from start to finish. 351 00:20:22,855 --> 00:20:25,089 This way they can check that each piece 352 00:20:25,091 --> 00:20:30,394 Fits perfectly before moving onto the next. 353 00:20:30,396 --> 00:20:33,197 But if they did that, the twisting track itself 354 00:20:33,199 --> 00:20:36,133 Would block key access points, 355 00:20:36,135 --> 00:20:37,768 Preventing their biggest crane 356 00:20:37,770 --> 00:20:40,471 From reaching several crucial sections. 357 00:20:43,343 --> 00:20:47,044 Their only option is to leave gaps in the track 358 00:20:47,046 --> 00:20:48,679 And fill them in later. 359 00:20:51,084 --> 00:20:54,185 But it's a high-risk strategy. 360 00:20:54,187 --> 00:20:57,455 If the missing pieces don't fit perfectly, 361 00:20:57,457 --> 00:21:00,324 They might have to remove several sections, 362 00:21:00,326 --> 00:21:02,727 Undoing weeks of hard work. 363 00:21:06,566 --> 00:21:07,865 Coming down. 364 00:21:09,502 --> 00:21:13,004 Ironworker grace ryba is one of the team members tasked 365 00:21:13,006 --> 00:21:16,040 With bridging the gaps in the track. 366 00:21:16,042 --> 00:21:19,977 There's barely any room to maneuver the cranes. 367 00:21:19,979 --> 00:21:21,612 That's it. 368 00:21:21,614 --> 00:21:23,281 You don't have much space to begin with, 369 00:21:23,283 --> 00:21:26,350 Then you don't have much boom either, 370 00:21:26,352 --> 00:21:30,288 So you got to work with what you got. 371 00:21:30,290 --> 00:21:34,792 Narrator: It's vital that the last few sections fit perfectly in place. 372 00:21:37,163 --> 00:21:38,529 Man: All good! 373 00:21:41,000 --> 00:21:43,901 The first piece bridges half of the empty gap. 374 00:21:47,707 --> 00:21:50,908 Now for the moment of truth. 375 00:21:50,910 --> 00:21:52,610 Everything all nice, it's level? 376 00:21:55,548 --> 00:21:58,149 Slide down this side here. 377 00:21:58,151 --> 00:22:04,322 ♪ 378 00:22:04,324 --> 00:22:09,126 Okay. Yo, got a six-inch gap up here. 379 00:22:09,128 --> 00:22:12,296 Grace heads up to check the connection 380 00:22:12,298 --> 00:22:14,098 And finds a problem... 381 00:22:14,100 --> 00:22:16,334 Ryba: We're not aligned quite right. 382 00:22:16,336 --> 00:22:19,303 Narrator: ...A six-inch gap in the track. 383 00:22:19,305 --> 00:22:21,572 Ryba: Obviously, the track is the most vital, 384 00:22:21,574 --> 00:22:23,907 Important part of this whole experience. 385 00:22:23,909 --> 00:22:25,409 It's got to be bang on. 386 00:22:25,411 --> 00:22:27,478 It's got to line up just right. 387 00:22:30,183 --> 00:22:32,650 Narrator: They try to wrench the pieces together... 388 00:22:32,652 --> 00:22:39,824 ♪ 389 00:22:39,826 --> 00:22:41,525 But it doesn't work. 390 00:22:41,527 --> 00:22:44,195 Ryba: It's getting pretty difficult. 391 00:22:44,197 --> 00:22:48,366 Narrator: Grace decides to loosen the base of the column on one side, 392 00:22:48,368 --> 00:22:53,371 Allowing it to lean over and close the gap at the top. 393 00:22:53,373 --> 00:22:55,339 A very small little adjustment here 394 00:22:55,341 --> 00:22:56,874 Will push that column up top 395 00:22:56,876 --> 00:22:59,110 And push that track section over. 396 00:22:59,112 --> 00:23:02,446 Hopefully this is just enough. 397 00:23:02,448 --> 00:23:04,348 Narrator: But, despite their best efforts, 398 00:23:04,350 --> 00:23:06,951 The column bolts won't budge. 399 00:23:10,289 --> 00:23:12,923 [ grunting ] 400 00:23:12,925 --> 00:23:15,893 -Nothing. -[bleep] 401 00:23:15,895 --> 00:23:17,795 Oh [bleep] 402 00:23:17,797 --> 00:23:19,296 This is tight. [ grunts ] 403 00:23:31,611 --> 00:23:39,817 ♪ 404 00:23:39,819 --> 00:23:41,352 Narrator: In canada... 405 00:23:41,354 --> 00:23:42,753 Man: We're all good. 406 00:23:42,755 --> 00:23:46,223 This team of engineers and ironworkers is battling 407 00:23:46,225 --> 00:23:50,027 To construct the biggest dive roller coaster in the world. 408 00:23:52,632 --> 00:23:54,865 Limited space means they've had to build 409 00:23:54,867 --> 00:23:59,103 This giant structure out of sequence. 410 00:23:59,105 --> 00:24:01,405 But it's left a gap in the track. 411 00:24:01,407 --> 00:24:03,841 We got a six-inch gap up here. 412 00:24:03,843 --> 00:24:06,243 It's critical that the pieces fit together properly 413 00:24:06,245 --> 00:24:07,878 So that we have smooth transition. 414 00:24:07,880 --> 00:24:09,146 If they're not perfect, 415 00:24:09,148 --> 00:24:11,816 Then they've got to go back and make it perfect. 416 00:24:11,818 --> 00:24:13,451 Try that. 417 00:24:15,555 --> 00:24:17,888 Narrator: With a bit of quick thinking, 418 00:24:17,890 --> 00:24:22,827 Ironworker grace ryba uses a pole to get maximum leverage, 419 00:24:22,829 --> 00:24:26,797 Loosening the bolts at the base of one of the support columns. 420 00:24:26,799 --> 00:24:29,166 A little difference in the bottom where you're moving it 421 00:24:29,168 --> 00:24:33,838 Makes a huge difference up top where the track is. 422 00:24:33,840 --> 00:24:35,439 Okay, so that's loose. 423 00:24:35,441 --> 00:24:37,007 It takes several hours of work 424 00:24:37,009 --> 00:24:39,109 Before they wrestle their bolts in... 425 00:24:42,215 --> 00:24:45,015 And force the pieces of track together. 426 00:24:45,017 --> 00:24:50,554 ♪ 427 00:24:50,556 --> 00:24:52,423 It's a small victory... 428 00:24:52,425 --> 00:24:53,891 Yeah, it's good. 429 00:24:53,893 --> 00:24:55,659 ...And there's still a huge amount of track 430 00:24:55,661 --> 00:24:57,261 For the team to install. 431 00:24:57,263 --> 00:25:03,300 ♪ 432 00:25:03,302 --> 00:25:04,902 It's January. 433 00:25:08,574 --> 00:25:11,542 The team fights through the brutal canadian winter, 434 00:25:11,544 --> 00:25:14,845 With temperatures dropping as low as minus-20. 435 00:25:14,847 --> 00:25:18,949 ♪ 436 00:25:18,951 --> 00:25:22,019 We carry on. Hot, cold, rain, shine, snow, 437 00:25:22,021 --> 00:25:23,821 Rain, sleet -- it doesn't matter. 438 00:25:23,823 --> 00:25:26,957 We're carrying on. 439 00:25:26,959 --> 00:25:32,096 Narrator: Despite the ice and snow, they make good progress. 440 00:25:32,098 --> 00:25:36,166 Just one last critical piece of the puzzle remains -- 441 00:25:36,168 --> 00:25:39,136 A full loop-the-loop. 442 00:25:39,138 --> 00:25:41,372 The goal for today is to complete this loop 443 00:25:41,374 --> 00:25:45,075 And thus complete the roller coaster. 444 00:25:45,077 --> 00:25:47,945 Narrator: The yukon striker will be the first dive coaster 445 00:25:47,947 --> 00:25:51,315 In the world to feature a full vertical loop. 446 00:25:55,087 --> 00:25:58,289 This daring invention dates back almost as far 447 00:25:58,291 --> 00:26:00,491 As the roller coaster itself. 448 00:26:02,695 --> 00:26:06,597 On the very first roller coasters in the 1800s, 449 00:26:06,599 --> 00:26:10,701 Thrill seekers would coast down winding tracks in wooden carts. 450 00:26:12,805 --> 00:26:14,672 Engineers in paris pioneered 451 00:26:14,674 --> 00:26:18,609 The first permanent vertical loop in 1846. 452 00:26:22,682 --> 00:26:25,382 With the advent of modern steel engineering, 453 00:26:25,384 --> 00:26:28,485 Designers needed fewer supports to hold up the track 454 00:26:28,487 --> 00:26:32,556 And build higher and more daring loops than ever before. 455 00:26:32,558 --> 00:26:37,528 ♪ 456 00:26:37,530 --> 00:26:39,363 Everything's frozen. 457 00:26:41,100 --> 00:26:44,768 The temperature is down to minus-40 with your wind chill. 458 00:26:47,607 --> 00:26:49,139 Narrator: The team on-site start 459 00:26:49,141 --> 00:26:54,044 By hoisting each 15-ton loop section into place. 460 00:26:54,046 --> 00:26:57,615 Workers battle the big freeze to bolt them together. 461 00:26:57,617 --> 00:27:03,554 ♪ 462 00:27:03,556 --> 00:27:05,322 Swung over a bit. 463 00:27:05,324 --> 00:27:10,160 ♪ 464 00:27:10,162 --> 00:27:11,762 Last piece. 465 00:27:11,764 --> 00:27:17,735 ♪ 466 00:27:17,737 --> 00:27:20,537 It's like an adrenaline rush. [ laughs ] 467 00:27:20,539 --> 00:27:24,041 ♪ 468 00:27:24,043 --> 00:27:26,977 Just a couple feet, couple inches. 469 00:27:26,979 --> 00:27:32,416 Finally, after 11 months of hard labor... 470 00:27:32,418 --> 00:27:34,218 Yeah, that's awesome. 471 00:27:34,220 --> 00:27:38,055 ...The 3,600-foot-long track is complete. 472 00:27:41,060 --> 00:27:44,128 I feel like a million bucks. Yeah, we did it. 473 00:27:44,130 --> 00:27:45,929 It's, uh -- it's a great feeling, 474 00:27:45,931 --> 00:27:49,266 And it's lining up great. 475 00:27:49,268 --> 00:27:50,868 Time to celebrate. 476 00:27:50,870 --> 00:27:57,608 ♪ 477 00:27:57,610 --> 00:28:00,577 Narrator: It's mission accomplished for the ironworkers. 478 00:28:02,882 --> 00:28:06,450 Now, with 13 weeks to go until opening day, 479 00:28:06,452 --> 00:28:08,886 The build enters a new phase. 480 00:28:11,157 --> 00:28:13,824 The yukon striker's three passenger trains 481 00:28:13,826 --> 00:28:15,993 Have arrived from switzerland. 482 00:28:15,995 --> 00:28:18,529 They're approximately $1 million each, each train. 483 00:28:20,599 --> 00:28:23,734 Narrator: They're the pinnacle of coaster-car technology. 484 00:28:27,473 --> 00:28:32,710 But there's one thing that these innovative trains don't have -- 485 00:28:32,712 --> 00:28:34,445 Engines. 486 00:28:34,447 --> 00:28:36,246 Some people might think that the trains have motors, 487 00:28:36,248 --> 00:28:37,448 But that's not the case. 488 00:28:37,450 --> 00:28:40,417 The trains run on gravity. 489 00:28:40,419 --> 00:28:43,320 Narrator: Once the vehicle plunges over the big drop, 490 00:28:43,322 --> 00:28:46,423 The train's own momentum is the only thing propelling it 491 00:28:46,425 --> 00:28:50,527 Through all of the loops and turns. 492 00:28:50,529 --> 00:28:54,431 To pull the motorless trains up to the top of the lift hill, 493 00:28:54,433 --> 00:28:58,836 The team must install a giant lift chain. 494 00:28:58,838 --> 00:29:01,071 This hooks onto the bottom of the trains 495 00:29:01,073 --> 00:29:04,208 And drags them up to the highest point of the ride. 496 00:29:06,345 --> 00:29:07,878 The aim of the game that we're playing now 497 00:29:07,880 --> 00:29:09,346 Is to get the chain up to the top of the lift 498 00:29:09,348 --> 00:29:12,216 And connect it back up to itself. 499 00:29:12,218 --> 00:29:14,251 Narrator: But with the cold winter temperatures 500 00:29:14,253 --> 00:29:16,253 Still bearing down on them, 501 00:29:16,255 --> 00:29:19,757 The slightest mistake could be costly. 502 00:29:30,169 --> 00:29:35,172 ♪ 503 00:29:35,174 --> 00:29:38,275 Narrator: At canada's most popular theme park, 504 00:29:38,277 --> 00:29:41,245 This team of engineers is preparing to install 505 00:29:41,247 --> 00:29:43,881 A 700-foot-long lift chain 506 00:29:43,883 --> 00:29:48,118 Into the world's tallest dive coaster. 507 00:29:48,120 --> 00:29:50,387 With this being the biggest dive coaster in the world, 508 00:29:50,389 --> 00:29:52,456 It does need the longest lift chain. 509 00:29:52,458 --> 00:29:55,325 It weighs about eight tons when it's complete. 510 00:29:58,998 --> 00:30:02,266 Narrator: This is how they plan to do it. 511 00:30:02,268 --> 00:30:06,904 First, they'll run a thick cable up over the lift hill 512 00:30:06,906 --> 00:30:09,173 And back down the under side 513 00:30:09,175 --> 00:30:13,243 Then attach it via pulleys to a powerful crane. 514 00:30:13,245 --> 00:30:16,413 Next, they'll secure the cable to 23-foot lengths 515 00:30:16,415 --> 00:30:23,187 Of steel lift chain, each weighing 490 pounds. 516 00:30:23,189 --> 00:30:25,155 As the crane's winch retracts, 517 00:30:25,157 --> 00:30:27,891 It pulls the chain up the lift hill. 518 00:30:27,893 --> 00:30:31,628 They'll splice on new lengths of chain as they go. 519 00:30:31,630 --> 00:30:34,965 When the crane's hook maxes out, they secure the load, 520 00:30:34,967 --> 00:30:38,702 Reset the winch, and start again. 521 00:30:38,704 --> 00:30:42,139 But the longer the chain grows, the heavier it gets. 522 00:30:44,710 --> 00:30:46,643 We're trying to get as much pulled at one time 523 00:30:46,645 --> 00:30:48,478 As we can get. 524 00:30:48,480 --> 00:30:50,881 Narrator: Veteran coaster builder kevin jones 525 00:30:50,883 --> 00:30:53,984 Is in charge of installing the lift chain. 526 00:30:53,986 --> 00:30:56,687 It's a tight squeeze on this radius of this cable. 527 00:30:59,158 --> 00:31:04,061 After attaching the first section of chain to the cable, 528 00:31:04,063 --> 00:31:07,331 They bring in the crane. 529 00:31:07,333 --> 00:31:10,734 But it struggles to grip the hard, icy ground. 530 00:31:10,736 --> 00:31:16,707 ♪ 531 00:31:16,709 --> 00:31:19,710 -We're getting there. -Are you scared? 532 00:31:19,712 --> 00:31:23,614 Finally, everything is rigged and ready to go. 533 00:31:23,616 --> 00:31:26,016 Okay, let's, uh, tell them we're gonna start up. 534 00:31:26,018 --> 00:31:32,456 ♪ 535 00:31:32,458 --> 00:31:34,524 Narrator: The first 23-foot chain length 536 00:31:34,526 --> 00:31:37,761 Slides smoothly up the channel. 537 00:31:37,763 --> 00:31:42,366 They connect the next length with a hydraulic press. 538 00:31:42,368 --> 00:31:44,434 Okay, so go ahead, press. 539 00:31:47,506 --> 00:31:49,439 The powerful crane pulls the chain 540 00:31:49,441 --> 00:31:52,276 Up to the top of the lift hill with ease. 541 00:31:52,278 --> 00:32:01,418 ♪ 542 00:32:01,420 --> 00:32:04,621 432, travis. 543 00:32:04,623 --> 00:32:07,157 Man: Travis, coming over the crest. 544 00:32:07,159 --> 00:32:08,659 We're just going over the crest now, 545 00:32:08,661 --> 00:32:11,762 So we'll be approaching the sprocket shortly. 546 00:32:11,764 --> 00:32:14,765 Alright, to the top. 547 00:32:14,767 --> 00:32:16,633 Good to go. 548 00:32:16,635 --> 00:32:19,469 Narrator: Once they get the chain over the top sprocket, 549 00:32:19,471 --> 00:32:21,939 They're home free. 550 00:32:21,941 --> 00:32:24,174 Jones: We should have enough chain and enough pull in the crane 551 00:32:24,176 --> 00:32:29,780 To make a complete rotation around the top sprocket. 552 00:32:29,782 --> 00:32:36,586 Narrator: The crane gently pulls the chain towards the sprocket teeth. 553 00:32:36,588 --> 00:32:39,723 Man #2: Wait, slow down there, gates. 554 00:32:39,725 --> 00:32:44,761 The chain must line up with the sprocket teeth perfectly. 555 00:32:44,763 --> 00:32:46,964 Uh, you guys got anybody on the ground? 556 00:32:50,602 --> 00:32:53,870 Okay, good, keep going. 557 00:32:53,872 --> 00:32:55,505 Narrator: Success. 558 00:32:58,010 --> 00:33:00,911 The sprocket takes the weight of the chain, 559 00:33:00,913 --> 00:33:04,081 Feeding it back down the underside of the lift hill. 560 00:33:07,453 --> 00:33:10,387 Jones: Now that the chain's in the sprocket, 561 00:33:10,389 --> 00:33:13,056 It's all downhill from here. 562 00:33:13,058 --> 00:33:16,393 ♪ 563 00:33:23,502 --> 00:33:25,202 Narrator: It's late March. 564 00:33:27,339 --> 00:33:30,207 The worst of the canadian winter has passed. 565 00:33:32,378 --> 00:33:35,779 But before they can open the world's biggest dive coaster, 566 00:33:35,781 --> 00:33:39,516 The team faces one last challenge -- 567 00:33:39,518 --> 00:33:41,284 Safety testing. 568 00:33:41,286 --> 00:33:47,457 ♪ 569 00:33:47,459 --> 00:33:51,395 It rests on the shoulders of systems engineer colin mcmichael 570 00:33:51,397 --> 00:33:53,764 To put the coaster through its paces. 571 00:33:56,435 --> 00:34:00,437 Luckily, he has some willing volunteers. 572 00:34:00,439 --> 00:34:02,773 Mcmichael: We like to fill them up to about the armpits. 573 00:34:02,775 --> 00:34:04,441 We consider that about 70 kilograms, 574 00:34:04,443 --> 00:34:07,644 Which is our optimal testing weight. 575 00:34:07,646 --> 00:34:08,879 The dummies can't get hurt. 576 00:34:08,881 --> 00:34:10,981 Nothing can happen to them, so we like to put 577 00:34:10,983 --> 00:34:12,482 A lot of cycles on with the dummies 578 00:34:12,484 --> 00:34:14,618 So that when we put that first guest on, 579 00:34:14,620 --> 00:34:17,154 We're 100% confident that nothing's gonna happen. 580 00:34:20,993 --> 00:34:24,094 The team has spent three weeks proving that a single 581 00:34:24,096 --> 00:34:28,365 Unmanned train runs smoothly around the track. 582 00:34:28,367 --> 00:34:32,436 Now, they face a much tougher challenge -- 583 00:34:32,438 --> 00:34:35,872 Running all three trains at the same time. 584 00:34:35,874 --> 00:34:37,374 Mcmichael: We're ready to put all three trains on. 585 00:34:37,376 --> 00:34:40,043 This will be the first day we've done that. 586 00:34:40,045 --> 00:34:41,812 We need to test the ride as a whole. 587 00:34:41,814 --> 00:34:43,013 Under normal operating conditions, 588 00:34:43,015 --> 00:34:44,714 We're gonna be running three trains. 589 00:34:46,685 --> 00:34:49,419 Narrator: Continuously-running coasters are essential 590 00:34:49,421 --> 00:34:51,321 To modern amusement parks 591 00:34:51,323 --> 00:34:55,258 As a way of keeping long lines to a minimum, 592 00:34:55,260 --> 00:34:57,861 And with safety a number-one priority, 593 00:34:57,863 --> 00:35:03,567 Engineers have to make sure the trains can't collide. 594 00:35:03,569 --> 00:35:05,402 It's very important for us to make sure that the ride 595 00:35:05,404 --> 00:35:06,970 Responds the way it should respond 596 00:35:06,972 --> 00:35:09,239 When we have things happen, like a fuse blow 597 00:35:09,241 --> 00:35:11,208 Or a wire break or a sensor fail, 598 00:35:11,210 --> 00:35:13,410 So that the ride stops in a safe way. 599 00:35:13,412 --> 00:35:14,678 All clear? 600 00:35:16,715 --> 00:35:20,383 Narrator: If a train get stuck on the yukon striker's track, 601 00:35:20,385 --> 00:35:25,589 It's vital that they're able to stop the oncoming train behind. 602 00:35:25,591 --> 00:35:31,228 These are moving machines, and machines can be dangerous. 603 00:35:31,230 --> 00:35:33,029 We never know who's gonna be coming on the ride. 604 00:35:33,031 --> 00:35:34,764 You know, it could be my boss. 605 00:35:34,766 --> 00:35:36,566 It could be my kids. 606 00:35:36,568 --> 00:35:38,335 Narrator: If this critical safety system 607 00:35:38,337 --> 00:35:42,172 Isn't successfully tested over 2,000 times, 608 00:35:42,174 --> 00:35:44,941 The ride can't open to the public. 609 00:35:54,720 --> 00:35:59,990 ♪ 610 00:35:59,992 --> 00:36:01,558 Clear. 611 00:36:01,560 --> 00:36:04,694 Narrator: At canada's biggest theme park, a team of engineers 612 00:36:04,696 --> 00:36:08,698 Is testing the world's fastest dive coaster. 613 00:36:08,700 --> 00:36:10,667 Mcmichael: When you come here for the day, 614 00:36:10,669 --> 00:36:12,969 We hope you leave in the exact same condition you showed up, 615 00:36:12,971 --> 00:36:15,839 Except with a smile on your face. 616 00:36:15,841 --> 00:36:17,974 Narrator: To make sure three trains can run around 617 00:36:17,976 --> 00:36:21,444 The track simultaneously without colliding, 618 00:36:21,446 --> 00:36:22,846 Colin's team must test 619 00:36:22,848 --> 00:36:26,783 The coaster's automatic braking system. 620 00:36:26,785 --> 00:36:28,919 So, just how do you stop a train 621 00:36:28,921 --> 00:36:31,521 On the world's fastest dive coaster? 622 00:36:35,294 --> 00:36:39,996 The trains themselves don't have any brakes. 623 00:36:39,998 --> 00:36:43,400 Instead, they rely on a series of special brake sections 624 00:36:43,402 --> 00:36:45,402 Distributed around the track. 625 00:36:48,507 --> 00:36:50,840 As the train approaches a brake section, 626 00:36:50,842 --> 00:36:54,044 First, a metal fin on the underside of the train 627 00:36:54,046 --> 00:36:57,814 Passes through a row of magnets. 628 00:36:57,816 --> 00:37:00,717 The magnetic field drags at the fin, 629 00:37:00,719 --> 00:37:03,687 Slowing the train down. 630 00:37:03,689 --> 00:37:08,992 But this contact-free system can't completely stop the train, 631 00:37:08,994 --> 00:37:11,561 So next, mechanical brakes clamp 632 00:37:11,563 --> 00:37:14,864 Onto the underside of the train to slow it down further 633 00:37:14,866 --> 00:37:17,000 Or bring it to a stand-still. 634 00:37:17,002 --> 00:37:22,339 ♪ 635 00:37:22,341 --> 00:37:26,009 The track has three brake sections in total -- 636 00:37:26,011 --> 00:37:28,445 One for each train. 637 00:37:28,447 --> 00:37:29,946 Once it's running, it's running, 638 00:37:29,948 --> 00:37:31,281 But once we get into these points, 639 00:37:31,283 --> 00:37:35,085 We can stop the trains if we need to stop them. 640 00:37:35,087 --> 00:37:37,887 Narrator: As the three trains move around the track, 641 00:37:37,889 --> 00:37:40,123 Hundreds of sensors act as eyes 642 00:37:40,125 --> 00:37:43,927 For the coaster's central control system. 643 00:37:43,929 --> 00:37:46,496 What these proximity switches do is see where the trains 644 00:37:46,498 --> 00:37:49,332 Are throughout the entire course of the track. 645 00:37:49,334 --> 00:37:51,401 The processors will make decisions 646 00:37:51,403 --> 00:37:52,769 On where to allow trains to go 647 00:37:52,771 --> 00:37:54,204 And where not to allow them. 648 00:37:56,208 --> 00:37:59,509 Narrator: If the system detects a stopped train ahead, 649 00:37:59,511 --> 00:38:01,645 It's programmed to automatically engage 650 00:38:01,647 --> 00:38:05,615 The necessary brake section, preventing a collision. 651 00:38:05,617 --> 00:38:11,154 ♪ 652 00:38:11,156 --> 00:38:14,224 It works, in theory, but now it's time for colin 653 00:38:14,226 --> 00:38:17,627 To put this crucial safety system to the test. 654 00:38:20,032 --> 00:38:22,699 He commands a brake section to stop a train 655 00:38:22,701 --> 00:38:24,868 As it reaches the end of the course. 656 00:38:24,870 --> 00:38:34,010 ♪ 657 00:38:34,012 --> 00:38:37,147 There's indications on the panel of where they are, 658 00:38:37,149 --> 00:38:40,750 And I can visually confirm that that's where the train is. 659 00:38:40,752 --> 00:38:44,254 ♪ 660 00:38:44,256 --> 00:38:45,722 Narrator: The previous brake section 661 00:38:45,724 --> 00:38:49,059 Should now stop the oncoming train in its tracks. 662 00:38:51,096 --> 00:38:53,430 Let the next train come around. 663 00:38:53,432 --> 00:38:56,766 Right on cue, the control system kicks in. 664 00:38:56,768 --> 00:39:01,771 ♪ 665 00:39:01,773 --> 00:39:06,309 The train stops before it can go any further, 666 00:39:06,311 --> 00:39:08,712 Preventing a collision. 667 00:39:08,714 --> 00:39:10,847 Everything's stopping where it's supposed to stop. 668 00:39:10,849 --> 00:39:14,784 Everything's going where it's supposed to go. 669 00:39:14,786 --> 00:39:17,721 Narrator: It's a good start. 670 00:39:17,723 --> 00:39:21,424 Now they must do it hundreds more times to prove 671 00:39:21,426 --> 00:39:24,928 That the entire system is reliable and safe. 672 00:39:27,833 --> 00:39:31,134 ♪ 673 00:39:31,136 --> 00:39:35,438 After 14 days of testing, the yukon striker will finally 674 00:39:35,440 --> 00:39:38,441 Take its first human passengers for a ride. 675 00:39:40,946 --> 00:39:45,181 The public aren't allowed on until testing is complete, 676 00:39:45,183 --> 00:39:49,119 So the engineers themselves will take the plunge. 677 00:39:49,121 --> 00:39:50,954 -You guys ready? -Yeah. 678 00:39:50,956 --> 00:39:52,222 We good? We ready? 679 00:39:52,224 --> 00:39:53,723 -Ready. -Ready. 680 00:39:55,093 --> 00:39:57,127 Mcmichael: We're about to go on our first ride. 681 00:39:57,129 --> 00:39:58,528 The maiden voyage. 682 00:39:58,530 --> 00:40:00,630 First run. 683 00:40:00,632 --> 00:40:02,399 Lot of hard work's gone in the last couple years 684 00:40:02,401 --> 00:40:04,033 To get to this point. 685 00:40:06,171 --> 00:40:08,104 Narrator: The human body is far more fragile 686 00:40:08,106 --> 00:40:09,873 Than a water-filled dummy. 687 00:40:12,210 --> 00:40:16,613 Their lives are in the hands of everyone who built this coaster. 688 00:40:16,615 --> 00:40:23,586 ♪ 689 00:40:23,588 --> 00:40:30,493 ♪ 690 00:40:30,495 --> 00:40:32,662 Wow. 691 00:40:32,664 --> 00:40:42,505 ♪ 692 00:40:42,507 --> 00:40:46,843 Narrator: Finally, the yukon striker delivers its first thrills. 693 00:40:47,212 --> 00:40:48,578 [ man laughs ] 694 00:40:50,015 --> 00:40:51,781 [ laughs ] 695 00:40:51,783 --> 00:40:58,922 ♪ 696 00:40:58,924 --> 00:41:00,757 Whoo. 697 00:41:00,759 --> 00:41:06,996 ♪ 698 00:41:06,998 --> 00:41:08,264 Wow. 699 00:41:08,266 --> 00:41:12,469 ♪ 700 00:41:12,471 --> 00:41:14,137 Whoo. 701 00:41:14,973 --> 00:41:16,306 That's amazing. 702 00:41:17,709 --> 00:41:19,576 It's really working those brakes. 703 00:41:19,578 --> 00:41:21,044 [ laughs ] 704 00:41:22,981 --> 00:41:24,180 I think we're gonna have to go on it again, 705 00:41:24,182 --> 00:41:25,248 Just to double check. 706 00:41:25,250 --> 00:41:28,485 You know, maybe we missed something. 707 00:41:28,487 --> 00:41:31,387 It's a phenomenal ride. I think it's gonna be a big hit. 708 00:41:34,459 --> 00:41:36,793 Narrator: Four weeks later, and it's opening day 709 00:41:36,795 --> 00:41:40,296 At canada's wonderland. 710 00:41:40,298 --> 00:41:42,799 Thousands of visitors flood to the park... 711 00:41:44,536 --> 00:41:46,102 [ cheers and applause ] 712 00:41:46,104 --> 00:41:49,806 ...All eager to ride the record-breaking new coaster. 713 00:41:52,077 --> 00:41:53,910 The ride was fantastic. It was so much fun. 714 00:41:53,912 --> 00:41:55,445 It was so fast. 715 00:41:55,447 --> 00:41:57,380 Everything we had hoped for. 716 00:41:57,382 --> 00:41:59,949 Can't wait to ride it again. It was really good. 717 00:41:59,951 --> 00:42:02,485 We've been waiting a long time to see this coaster and ride it, 718 00:42:02,487 --> 00:42:04,587 So it was a blast to finally get on. 719 00:42:06,625 --> 00:42:08,191 Switzer: To hear them talk about it afterwards -- 720 00:42:08,193 --> 00:42:10,593 How amazing that was, what a great experience -- 721 00:42:10,595 --> 00:42:12,529 Is very rewarding. 722 00:42:12,531 --> 00:42:14,297 In the end, we got it all done. 723 00:42:14,299 --> 00:42:16,232 [ applause ] 724 00:42:16,234 --> 00:42:19,636 Narrator: After five years of planning, designing, 725 00:42:19,638 --> 00:42:21,604 Building, and testing, 726 00:42:21,606 --> 00:42:25,708 The world's fastest dive coaster is open for business. 63982

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