Wooden roller coaster

This relatively quiet age of coaster design following the Great Depression was brought to an end by The Racer at Kings Island, which opened in 1972 and sparked a second "Golden Age" of wooden coaster design that continues today. After their success with the Racer at Kings Island, the Philadelphia Toboggan Company (PTC) constructed another 9 roller coasters over the next decade. About half were small family coasters, two were racing coasters similar to the Racer, and two were out and back coasters with custom designs. One of these, Screamin' Eagle at Six Flags St. Louis, was the last coaster designed by John Allen before his retirement. After these coasters, PTC stopped producing roller coasters, but continues to produce wooden roller coaster trains as Philadelphia Toboggan Coasters. Their distinctive rectangular cars are widely used on wooden coasters around the world.

A notable non-PTC coaster built during this time was The Beast at Kings Island. After John Allen refused to design the coaster in lieu of retirement, Kings Island built the coaster themselves, with the coaster designed by Al Collins and Jeff Gramke and construction overseen by Charlie Dinn. Rather than a typical out and back layout, the coaster sprawled over the woods at the back of the park, using the terrain to create an elevation change from lowest to highest point of 201 feet, even though the coaster was only 118 feet tall.[3] The coaster also had two lift hills which, while common for mine train coasters at the time, was uncommon for wooden coasters. Opening in 1979, the coaster was, and still is, the longest wooden roller coaster in the world at 7,359 feet. Another significant wooden coaster of this era was the racing American Eagle at (now) Six Flags Great America, built by Intamin in 1981, which still holds the records for racing wooden coasters of height (127 ft), length (4650 ft), speed (66 mph), and drop (147 ft).

After the surge in the 1970s, wooden coasters construction became stagnant due to the steel roller coaster being much more popular. Most original coasters during this time were designed by William Cobb, such as Monstre at La Ronde. Another trend during the 1980s was relocating old wooden coasters in danger of being destroyed. Charlie Dinn, who formed Dinn Corporation after leaving Kings Island in 1984, oversaw some of these relocations, including the relocation of The Rocket from Playland Park to Knoebels Amusement Resort in Pennsylvania. It now operates as the Phoenix and is ranked highly on wooden coaster polls.

In 1988, Charlie Dinn started a partnership with Curtis D. Summers to design and build new wooden coasters. Between 1988 and 1991, the pair designed and built 10 new wooden coasters. While most were of typical wooden coaster size, a few set coaster records. Hercules at Dorney Park & Wildwater Kingdom, built in 1989, had the tallest wooden coaster drop at 150 feet. Texas Giant at Six Flags Over Texas and Mean Streak at Cedar Point were large wooden coasters with similar layouts, with the later opening as the tallest wooden coaster in the world at 161 feet. After a dispute during construction of Pegasus at Efteling, Dinn Corporation closed down and the partnership ended.

Custom Coasters International was formed in 1991 by Denise Dinn-Larrick (daughter of Charlie Dinn), her brother Jeff Dinn, and her husband Randy Larrick. After the closure of Dinn Corporation, several other designers joined CCI. The company's first coaster, Kingdom Coaster at Dutch Wonderland, was a small family coaster that stood only 55 feet high. As time went on, they began to design larger coasters. One of their earlier coasters that was well received was The Raven at Holiday World. Custom Coasters took on increasingly high numbers of wooden coaster projects, including 7 coasters in 2000 alone (The Boss at Six Flags St. Louis, which was the largest with a 153-foot drop and almost a mile of track; Medusa at Six Flags Mexico; Mega Zeph at the defunct Six Flags New Orleans; Boulder Dash at Lake Compounce; Villain at the defunct Geauga Lake; Hurricane: Category 5 at the defunct Myrtle Beach Pavilion; and The Legend at Holiday World).

CCI's coaster designs included both out and back layouts like Hoosier Hurricane at Indiana Beach as well as more twisted layouts like Megafobia at Oakwood Theme Park. Megafobia was also the company's first coaster outside the United States. CCI coasters were also unique at the time for sometimes featuring angle iron support structures rather than wooden beams (the track remains the same as other wooden coasters). Most CCI coasters ran Philadelphia Toboggan Company trains, although some, like The Boss at Six Flags St. Louis, run trains from the German manufacturer Gerstlauer.

In 2002, Custom Coasters declared bankruptcy while building the New Mexico Rattler at Cliff's Amusement Park. The company left a significant legacy on the coaster industry. The high number of wooden coasters they constructed, 34 over their decade of operation, helped to rekindle interest in the wooden roller coasters and allowed modern wooden coaster designers to thrive. Designers from CCI went on to form modern wooden coaster design firms, like Great Coasters International, The Gravity Group, and the wooden coaster department at S&S Worldwide. Many of their coasters rank highly in wooden coaster polls, including Shivering Timbers at Michigan's Adventure and Boulder Dash at Lake Compounce. In 2013, Boulder Dash was rated the number one wooden roller coaster in the world by Amusement Today.

Great Coasters International (GCI) was formed in 1994 by Mike Boodley and Clair Hain, Jr, the former of whom was a designer at Custom Coasters prior to GCI. The first coaster was Wildcat at Hersheypark which opened in 1996. Since then, they have become one of the major wooden coaster designers in the industry, with award-winning coasters like Lightning Racer at Hersheypark and Thunderhead at Dollywood. GCI's coasters feature highly twisted layouts with many crossovers, and usually use GCI's own wooden coaster trains called Millennium Flyers. Their designs are inspired by coasters from the 1920s, specifically those by Fred Church and Harry Traver, and the company focuses on making the structures of their coasters aesthetically appealing and artistic.

In 2001, Swiss steel coaster designer Intamin began producing wooden roller coasters using prefabricated track. Their wooden coasters are known for large amounts of airtime (including ejector airtime), smooth ride experiences, and steep drops. T Express in Everland is currently the tallest wooden coaster in the world at 183 feet tall. While only having built 4 wooden coasters, all are praised by coaster enthusiasts, with all 4 being within the top 20 wooden coasters in the world on Mitch Hawkers poll. Since 2010, El Toro at Six Flags Great Adventure, which opened in 2006, has been ranked the number one wooden coaster in the world on Mitch Hawkers poll.

Notable designers from the former Custom Coasters International formed The Gravity Group and in 2005 opened Hades (now Hades 360) at Mt. Olympus Water and Theme Park. The coaster features highly unique elements, including an airtime filled pre-lift section, an 800-foot tunnel underneath a parking lot, and a 90 degree banked turn. In 2006, The Gravity Group built The Voyage at Holiday World, a large wooden coaster which stood 163 feet tall, has over a mile of track, 3 90 degree banked turns, and has been ranked the number one wooden coaster in the world by Amusement Today five times. Many of Gravity Groups coasters are highly unique and custom built for the park, such as Twister at Gröna Lund, which has a highly compact layout to fit in the parks small footprint. Their coasters have become very popular in China, in which 12 coasters have been built since 2009.

Rocky Mountain Construction (RMC) has recently been revolutionizing the modern wooden coaster. In 2011, they renovated the Texas Giant, which had become very rough and hard to maintain, into a steel roller coaster. This treatment became popular and was later applied to other aging roller coasters such as Iron Rattler and Twisted Colossus. In addition, RMC designs and builds their own original wooden coasters. In 2016, the company opened the world's first launched wooden roller coaster, Lightning Rod which opened at Dollywood in 2016, and features a magnetic launch of 45 mph up a 200' hill, similar to the magnetic lift on Maverick.

From 2000 to 2006, Son of Beast had a steel vertical loop (center)

In 2000, Kings Island opened Son of Beast. Designed by Werner Stengel and built by the Roller Coaster Corporation of America, the roller coaster broke many world records. With a height of 218 feet (66 m), it was the first wooden roller coaster to top 200 feet (61 m).[4] It was also the first modern wooden roller coaster to feature an inversion, a 90-foot (27 m) vertical loop, which was made of steel.[5] The ride was well-received but was plagued by a number of incidents, including two that were serious, eventually leading to its demise in 2012.[6][7][8]

In the 2010s, a new era of wooden roller coasters came about with the introduction of Topper Track developed by Rocky Mountain Construction. The new technology replaced the flattened steel strip and upper two layers of wood traditionally used in wooden track design with a steel box,[9] which led to rides like the triple-inverting Outlaw Run at Silver Dollar City in 2012.[10][11] Others like Wildfire at Kolmården Wildlife Park and Goliath at Six Flags Great America soon followed.[12][13] Topper Track provides the added benefit of smoother rides and lower maintenance costs.

The Gravity Group also designed five wooden coasters with a single inversion: these include coasters at each of three Oriental Heritage theme parks in China, all named Jungle Trailblazer,[14][15][16] as well as Mine Blower in Fun Spot Kissimmee[17] and the conversion of their existing Hades 360 in Mt. Olympus Water & Theme Park.[18]

The common choice of wood selected for modern wooden roller coasters worldwide is southern yellow pine,[19] a softwood abundant in the southern United States from eastern Texas to Virginia.[20] It is known for its strength, which comes from its extremely dense properties.[19] Southern pine is also easy to cut and responds well to pressure treatment.[19]

Companies like Intamin and Rocky Mountain Construction began using prefabricated track in the 2010s. The design borrows the principles of steel coaster manufacturing and applies them to wood.

Traditional wooden coaster track is typically built on site. It is cut as needed, bent to the proper shape, and mounted layer-by-layer to the support structure with steel running plates. Prefabricated track, on the other hand, is manufactured in a factory, temperature-controlled setting. It is made of many thin layers of wood that are glued together and then laser cut to exact specifications. The track is made in 25-foot (7.6 m) sections, which have special joints on the ends to allow them to snap together. The result is generally higher precision than what could be achieved by hand, leading to a smoother ride and reduced cost surrounding construction and maintenance. In addition, unlike traditional wooden coasters which feature bare metal wheels, the trains for a prefabricated wooden coaster have wheels made of polyurethane treads, similar to a steel coaster.