Behind-the-Scenes: Hurler Receives New Track

Carowinds, the ultimate destination for family fun, offers an array of rides and attractions suitable for all ages, including 14 thrilling roller coasters. Among these, Hurler celebrates 30 years in 2024.

Hurler Celebrates 30 Years of Thrills

In 1993, Carowinds announced a significant expansion, the first since Paramount's acquisition in 1992, introducing a new themed area named Wayne's World. This addition, inspired by the Paramount film, featured the relocation of Scream Weaver and the debut of attractions such as Stan Mikita's Diner (Juke Box Diner), Rock Shop (Thrills Shop), and Hurler, the centerpiece of the new area. Designed by International Coasters Inc., Hurler is a wooden coaster stretching 3,157 feet, reaching speeds of up to 50 mph, and featuring an 80-foot drop.

Wooden Roller Coasters Receive RMC

Hurler, alongside Woodstock Express and Carolina Goldrusher, completes Carowinds' collection of wooden coasters, bridging the gap between rides designed for children and large thrills such as Fury 325.

All rides and attractions undergo Routine Maintenance by Carowinds, with wooden structures requiring more attention due to their susceptibility to weather.

"Wood deteriorates over time due to stress from vibration, wind, rain, sunlight, and other weather elements," explained Steve Jackson, director of maintenance and construction at Carowinds. "Eventually, replacing the structure and track is necessary to ensure safety and proper operation."

Accelerometer testing aids in identifying repair needs on all of Carowinds' roller coasters. Wooden coasters are adjusted more frequently due to weather impacts. Persistent issues flagged by testing can lead the technicians to rebuild entire coaster sections.

New Season. New Track.

Historically, Carowinds outsourced wooden coaster track rebuilds. In 2014, Great Coasters International refurbished Hurler's 180-degree turn, located immediately after the ride's first descent. For 2024, Carowinds' in-house maintenance team is rebuilding Hurler's back curve to enhance the ride experience.

Track Removal 

WinterFest visitors observed the dismantling of the ride's section, which began in late 2023. Maintenance associates used chainsaws for quick removal.

"Chainsaws make the removal process much faster, rather than unbolting each track piece," Jackson said.

Track Rebuild

In January, the maintenance team at Carowinds began reconstructing the latter half of Hurler's structure. Once the structure is finalized, specialists ensure its measurements before proceeding to the track installation.

The 30-year-old attraction is constructed with a nine-layer track. Hurler's first seven layers are set in an overlapping arrangement to reinforce the structure, preventing contiguous joints from running through the top of the track to the bottom of the track.

"Overlapping wood not only supports the structure but adds extra strength, security, and stability to each stack of track," said Jackson.

The top two layers, known as the "lip layer," extend slightly beyond the first seven, forming an "up stop" that prevents the roller coaster train from derailing. After installing all nine wood layers, the track's steel components are installed with large 16-inch bolts.

Following the completion of the rebuild, the maintenance team meticulously checks each new track segment with various measuring instruments to ensure perfect alignment with the coaster trains. After passing verification, Carowinds' operations team inspects the attraction before it reopens to guests.

Rebuilding track segments like this offers the opportunity to fine-tune the ride. 

"We took the opportunity to smooth out and slightly adjust the curve," Jackson said. "It will offer our guests a smoother and more thrilling experience."

Enjoy the excitement of Hurler, along with nearly 60 other rides and attractions, throughout the summer with a 2024 Carowinds Silver Pass, now available for $95.