Last week, we discussed the process of turning ideas into concept sketches and scale models. I used the example of Epcot to show how a project goes from an artist’s concept sketch to the model shop, and then finally how those both compare to the finished product.

But just how is it that a project goes from a model to a finished product? This week, we’ll take a closer look at that process.

Once the model has been signed off on, the construction is usually bid out to a contractor to actually build the building(s) that will house the attraction. But, with the nature of some of WDI’s projects, it isn’t always so cut and dry to build some of the structures that have been designed, but we’ll get to that in a minute.

First, the ground on which the future attraction will one day sit must be cleared and prepared for construction. If the attraction is replacing an existing site in one of the Disney parks, this is when those infamous construction walls go up, while the die-hard fans curiously try to peer over them to see what is going on.

Ground prep consists of clearing away any old structures that previously existed, and hauling away any debris from their demolition. The land is then leveled or graded as called for by the plans. Foundations are usually then poured for any structures that will be built as part of the attraction.

In the case of the typical dark ride, a simple warehouse is usually constructed that will house the show scenes of the attraction. Take the Haunted Mansion as an example. While the only portion of the attraction that the guests can see from the outside is the Mansion façade, the actual ride is housed in a giant warehouse not visible from the guest areas of the park.

This warehouse would be completely constructed according to the schematic plans created by the attraction’s designers. Once this structure is completed to specifications, all of the various pieces of scenery, ride vehicles, and so forth are shipped to the site to be prepared for installation.

In the case of the Haunted Mansion, the warehouse is divided up into several rooms, each serving as a separate scene. The Imagineers will then install the special effects, animatronics, and anything else called for in the various scenes. At the same time, the ride system is tweaked and installed throughout the show building.

But what about the attractions that aren’t as typical? Splash Mountain, for example, provided the construction crew with the challenge of building an entire mountain to house this epic attraction. This required a slightly more complicated approach.

First, a primary steel structure was constructed on the site that served to support the mountain façade. The scale model for Splash Mountain was then cut up into pieces and scanned into a computer to create a three dimensional wire-frame model of the mountain. This information is compiled and sent to a special machine that bends pieces of rebar into specific shapes. These rebar pieces are then welded together to create a sort of cage. These rebar cages are then flown piece by piece to the construction site where they are attached to the steel structure already in place.

Like a giant puzzle, these rebar cages are welded together and begin to form the shape of the mountain. Once the mountain begins to take shape, the structure is covered in concrete and plaster, which is then sculpted by artisans and painted. Meanwhile, the interior of the mountain is divided up into the various scenes as the ride system, show scenes and special effects are installed.

After several weeks of installation of the ride system, special effects, and show scenes, the attraction is finally turned on and the final stage begins… The all important test and adjust stage. This is where the designers finally learn whether or not this is really going to work after all!

Next week, we’ll wrap up this series with a discussion on what goes on during the test and adjust period. Until then, I’ll see ya real soon!