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Arrow Development

Arrow Development was an American amusement park ride design and manufacturing company, founded on November 16, 1945, in Mountain View, California, by engineers Angus "Andy" Anderson, Ed Morgan, William Hardiman, and Karl Bacon, and renowned for pioneering innovations in roller coasters, flume rides, and dark attractions that shaped the modern theme park industry. The company initially focused on smaller attractions like merry-go-rounds and portable rides for local fairs, with its first project being a San Jose Merry-Go-Round in 1947 for $3,500, but gained prominence through a pivotal collaboration with Walt Disney starting in 1953. Arrow's engineers developed groundbreaking tubular steel track and polyurethane-wheeled vehicles for the Matterhorn Bobsleds at Disneyland, which opened in 1959 as the world's first tubular steel roller coaster and a landmark in ride technology. This partnership expanded to include iconic dark rides such as Snow White's Scary Adventures, Peter Pan's Flight, Dumbo the Flying Elephant, Mad Tea Party, Casey Jr. Circus Train, Pirates of the Caribbean, It's a Small World, and The Haunted Mansion, establishing Arrow as a key supplier for Disney's immersive attractions. In the post-Disney era, Arrow innovated further with the introduction of rides in the 1960s—pioneering the genre with El Aserradero, the first , at in 1963— and mine train coasters in the 1970s, such as Hersheypark's , which opened in 1974 as a 1,600-foot track reaching 35 mph for $975,000. The company also advanced looping roller coasters, including at in 1976, Arrow's first with a vertical loop,) and hydroflume rides like Hersheypark's Coal Cracker in 1973, which featured two lift hills and held 100,000 gallons of water at a cost of $811,000. By the , Arrow had evolved into through mergers, such as with Huss Maschinenfabrik in 1981, expanding its portfolio to hundreds of installations worldwide, including the pioneering tubular steel designs that influenced global amusement engineering. Arrow Dynamics faced financial challenges, declaring in December 2001, after which its assets were acquired by S&S Power in 2002 to form S&S Arrow, and later restructured under S&S-Sansei Technologies in 2012. Despite its closure, Arrow's legacy endures through its revolutionary contributions to ride safety, smoothness, and thrill, as documented in enthusiast retrospectives like the American Coaster Enthusiasts' 2016 film The Legacy of Arrow Development, which highlights the company's role in transforming post-World War II amusement parks into sophisticated theme park experiences.

History

Founding and Early Operations (1945–1953)

Arrow Development was incorporated on November 16, 1945, in , by Angus "Andy" Anderson, Edgar "Ed" Morgan, William "Bill" Hardiman, and Karl Bacon. The four founders, who had previously collaborated as foremen at the Joshua Hendy Iron Works in Sunnyvale—a involved in wartime —pooled their skills in , mechanics, machining, and accounting to establish the company on a newly purchased parcel of land. Construction of their initial cinder-block facility was completed by August 1946, marking the start of operations in the burgeoning industrial region later known as . In its early years, Arrow operated primarily as a general , capitalizing on the post-World War II economic recovery by producing precision parts for diverse industries. The company initially manufactured components such as Navy blowers for test furnaces, audio oscillators for , and crop-dusting kits for , with its workforce expanding from six to sixteen employees by the early . A significant setback occurred in 1948 when declared bankruptcy, leaving Arrow with unpaid invoices and prompting a pivot to alternative contracts, including $5,000 worth of work from Dura Bond Bearing to stabilize finances. These efforts underscored the firm's versatility in custom fabrication for and sectors amid the era's industrial boom. By the late 1940s, Arrow began experimenting with amusement devices, transitioning from industrial work to prototyping small-scale attractions for local venues. Their first major foray into this area came in 1947 with a to build a 20-foot merry-go-round and accompanying kiddie ride for Alum Rock Park in —innovative for using durable construction instead of traditional wood. Designed by and , who drew on observations of existing carnival rides, this project represented Arrow's initial prototype efforts in ride mechanics and marked their entry into the nascent amusement sector through custom engineering for regional fairs and parks. In 1952, they further tested these capabilities with "Lil’ Belle," a sternwheel paddle boat ride for Peralta Park in Oakland. The period was marked by key challenges, including limited startup funding that required the founders to share resources and rotate leadership roles, as well as stiff competition from established machine shops and manufacturers in the crowded market. These constraints, compounded by the lack of a mature amusement industry, steered Arrow toward specialized custom engineering solutions, honing their expertise in innovative prototyping that would prove pivotal in later opportunities, such as their 1953 collaboration with .

Disney Collaboration and Theme Park Breakthroughs (1953–1971)

In 1953, Walt Disney hired Arrow Development to design and manufacture several original attractions for Disneyland's , including prototypes for the Junior cars, leveraging the company's machine shop expertise in custom engineering. This partnership marked Arrow's entry into theme park innovation, with the firm delivering key elements like the track-guided vehicles for the series by Disneyland's 1955 opening. The collaboration quickly expanded, as Disney sought Arrow's precision to realize ambitious, immersive experiences beyond traditional amusement rides. A pivotal achievement came in 1959 with the , the world's first tubular , engineered by Arrow for . The project presented significant engineering challenges, including constructing the dual-track system within a 147-foot artificial mountain replica inspired by the , requiring innovative wheels and seamless integration of the bobsled vehicles to navigate steep drops and curves while maintaining safety and smooth operation. Arrow's tubular track design revolutionized coaster construction, allowing for tighter turns and higher speeds compared to wooden predecessors, and set a new industry standard. Arrow's expertise in ride systems shone in the 1964 New York World's Fair with the boat ride for "it's a small world," where the company developed the passenger boats and propulsion mechanism using water jets embedded in canal walls to boost capacity from 1,600 to over 3,000 guests per hour. After the fair, the attraction relocated to in 1966, with Arrow's patented guidance system ensuring reliable navigation through the global-themed scenes. Similarly, for The Haunted Mansion's 1969 debut at , Arrow constructed the transport system, enabling the Doom Buggy vehicles to deliver guests through the dark ride's ghostly illusions with precise, continuous motion. In 1960, Productions acquired one-third ownership of Arrow, providing financial stability to support ongoing projects while positioning the company as an in-house partner, though this led to tensions over creative control and . The partnership culminated in contributions to World's 1971 opening, including the audio-animatronic stage mechanisms for , which integrated moving figures and theatrical elements for the musical revue. By 1971, however, Disney shifted toward self-sufficiency, ending the direct collaboration after Arrow's systems had defined an era of theme park breakthroughs.

Expansion into Non-Disney Projects (1950s–1970s)

During the 1950s and 1960s, Arrow Development began securing independent contracts beyond its Disney partnerships, leveraging its reputation from early theme park innovations to attract clients at emerging regional parks. This diversification allowed the company to pioneer ride types tailored for broader audiences, emphasizing family-friendly thrills and operational efficiency. By the 1970s, Arrow's portfolio expanded significantly, incorporating advanced engineering that influenced global park designs. A landmark achievement was the development of the first modern log flume ride, El Aserradero, which opened at Six Flags Over Texas in 1963. This attraction featured log-shaped boats seating up to four riders, constructed from fiberglass to mimic wooden logs while ensuring durability and smooth flotation in a concrete trough. The ride's splashdown mechanics culminated in a steep 20-foot drop into a shallow pool, generating a dramatic water spray that enhanced the immersive, frontier-themed experience without excessive soaking. This design set the standard for log flumes worldwide, with Arrow installing over 50 similar systems by the mid-1970s. Arrow also innovated in mine train coasters, creating themed layouts that evoked underground mining adventures. The Runaway Mine Train at , debuting in 1974, exemplified this with its 2,429-foot steel track featuring a chain , banked turns, helices, and an underwater tunnel finale to simulate narrow mine shafts and sudden escapes. Unlike traditional wooden coasters, the tubular steel design allowed for close-to-ground contours and immersive scenery, accommodating families with gentle speeds up to 38 mph and no inversions. This model influenced subsequent mine trains, emphasizing narrative theming over extreme drops. In parallel, Arrow engineered family-oriented dark rides and transportation systems for international expositions and parks, prioritizing accessibility and scenic transport. At in , the company contributed to La Ronde's attractions, including the Rub-A-Tub raft ride, a gentle circular water feature using buoyant, round vessels for children to navigate shallow pools amid playful theming. These efforts extended to aerial systems like transports, facilitating efficient guest movement across large venues while integrating subtle thrills. Such projects underscored Arrow's versatility in non-coaster offerings during the late 1960s. Market expansion accelerated in the as Arrow delivered early coaster prototypes to parks like and , transitioning from wooden designs to more durable tubular tracks. At , initial collaborations in the decade laid groundwork for later innovations, while benefited from Arrow's hydro variants in its early years, blending water elements with coaster-like drops for milder experiences. These prototypes tested low-profile layouts and chain lifts, proving 's advantages in reliability and customization for regional operators. By the 1970s, internal research and development at Arrow focused on vertical looping concepts, with scale models and prototypes validating safe inversion mechanics for non-Disney applications. This culminated in the Revolution at Six Flags Magic Mountain in 1976, the first modern steel coaster with a full vertical loop, achieved through reinforced tubular tracks and precise g-force calculations to minimize rider discomfort. Tested on off-site prototypes, these advancements enabled Arrow to produce over a dozen looping coasters by decade's end, revolutionizing thrill ride engineering.

Corporate Transitions and Legacy (1970s–2002)

In 1973, founders Ed Morgan and Karl Bacon sold their interests in Arrow Development, marking the end of their direct involvement after nearly three decades of leadership that had transformed the company into a cornerstone of the amusement ride industry. The sale was to Industries, a of Penn Central, which sought to leverage Arrow's expertise for its own theme park development plans amid the growing post- expansion era. Under this ownership, Arrow continued to innovate but shifted focus toward broader market opportunities beyond its foundational Disney collaborations. By 1981, Rio Grande Industries divested Arrow through a merger with the German firm Huss Maschinenfabrik, creating Arrow-Huss to enhance international export capabilities and combine American coaster engineering with European ride manufacturing strengths. This partnership aimed to streamline operations and penetrate global markets more effectively, though financial pressures soon emerged. In 1985, Arrow-Huss filed for bankruptcy protection amid operational challenges, leading to a management buyout by 13 American executives the following year; this restructuring separated the U.S.-based coaster division, reestablishing it in Clearfield, Utah, as the independent Arrow Dynamics while Huss operations reverted to their original structure. Arrow Dynamics operated successfully for over a decade, producing landmark rides that solidified its reputation, but economic strains in the early culminated in a Chapter 11 bankruptcy filing in December 2001, with debts exceeding $2.2 million to major creditors. In October 2002, a bankruptcy court approved the sale of its assets for $1.9 million to , a ride manufacturer, effectively dissolving and integrating its technologies into S&S Arrow. S&S later became fully owned by in 2012, continuing elements of Arrow's legacy under the S&S – Sansei Technologies banner. Despite its dissolution, Arrow's influence endured profoundly in the amusement industry, as its pioneering tubular steel designs and engineering practices trained a generation of professionals who went on to shape competitors, including contributions to Intamin's advancements in the coaster wars. Engineers like Alan Schilke, who honed skills at Arrow before designing innovative coasters elsewhere, exemplified this ripple effect, ensuring Arrow's foundational role in modern thrill ride evolution persisted through its successors and alumni.

Innovations and Technologies

Tubular Steel Track Systems

Arrow Development pioneered the use of tubular steel track systems in roller coasters, debuting this innovation in 1959 with the at . Unlike traditional wooden tracks with railroad-style rails, the design employed welded steel tubes that formed a continuous, circular path for the wheels, enabling smoother operation and steeper banking angles. This breakthrough, engineered by company co-founders Ed Morgan and Karl Bacon, marked the world's first tubular steel roller coaster and set the foundation for modern coaster construction. The structural advantages of tubular steel tracks included significantly reduced vibration and friction compared to wooden predecessors, resulting in a more comfortable ride at higher speeds. The rigid, cylindrical structure provided greater strength and flexibility, allowing for tighter curves, steeper drops, and the eventual incorporation of inversions that wooden tracks could not safely support. Additionally, the modular design facilitated scalability, enabling integration into themed environments like artificial mountains without compromising structural integrity. Key to this was U.S. Patent 3,167,024, filed in 1960 and issued in 1965 to and , which detailed the bobsled-style ride system including the track configuration for enhanced and passenger . Manufacturing involved precision of tubes to create seamless sections, ensuring uniform and minimal wear on nylon-wheeled vehicles. By the 1970s, Arrow evolved the tubular steel track to support multi-loop configurations, as demonstrated in pioneering installations like the Revolution at Six Flags Magic Mountain in 1976, the first modern vertical looping coaster. This advancement permitted sustained higher speeds—up to 55 mph in early models—while mitigating derailment risks through improved wheel guidance and track rigidity. The technology's reliability enabled subsequent designs with multiple inversions, transforming roller coaster engineering and influencing industry standards for thrill rides.

Log Flume and Water Ride Designs

Arrow Development pioneered the modern log flume ride in 1963 with the installation of El Aserradero at Six Flags Over Texas, introducing a water-based attraction that simulated a lumber mill journey using controlled drops and splashes for thrill. This design evolved from earlier shoot-the-chutes rides, incorporating two chain-driven lifts to elevate fiberglass boats mimicking hollow logs, followed by gravity-powered descents into trough channels that guided riders safely toward splash pools. The boats, constructed from molded fiberglass, provided a lightweight yet sturdy vessel capable of carrying 4 to 6 passengers while maintaining stability during high-speed drops up to 30 feet. Key engineering elements focused on balancing excitement with and reliability, including precisely engineered rates to propel boats without excessive , achieved through inclined conveyor chains for uphill transport and open or concrete-lined for downhill runs. pools at the base of each drop were designed to absorb impact and generate signature water plumes, enhancing the sensory experience while minimizing rider soaking through angled entries and wave barriers. To ensure operational consistency, Arrow integrated systems that recirculated from reservoirs back to the tops, maintaining steady levels and velocities essential for repeatable ride cycles. Durability was a core priority in these designs, with corrosion-resistant hulls for boats and or coated metal structures for flumes and supports to withstand constant water exposure and environmental wear. These materials, combined with robust hydraulic pumps rated for continuous operation, allowed log flumes to operate reliably in outdoor settings, reducing maintenance needs and extending service life across multiple seasons. Building on the foundation, Arrow adapted the technology for variations like enhanced shoot-the-chute experiences in the , such as the dual-lift configuration at , which broadened appeal beyond themed lumber simulations to more generalized aquatic descents. This innovation marked a commercialization milestone, enabling non-Disney parks to implement scalable water attractions that combined hydraulic precision with passenger comfort.

Mine Trains and Family Coasters

Arrow Development introduced the mine train coaster concept in the mid-1960s, debuting the genre with the Runaway Mine Train at in 1966, designed by engineer . This innovation built on the company's expertise in tubular steel track systems, creating a family-oriented ride that simulated a runaway mining train through themed, low-thrill excursions. The trains consisted of cars styled as connected mine carts, each seating four passengers across two benches, providing an open-air experience that emphasized accessibility for all ages while integrating narrative elements of frontier mining adventures. The track engineering featured elevated tubular steel rails, allowing for smooth, gentle undulations with maximum heights of around 35 feet and circuit lengths of approximately 2,500 feet, as seen in the original Runaway Mine Train. These designs incorporated multiple lift hills and curving paths to maintain moderate speeds, with integrated brakes to control pacing and ensure consistent ride times, prioritizing rider comfort over velocity. Theming was seamlessly woven into the structure through elements like faux rockwork formations and tunnels, including the pioneering in the Runaway Mine Train, which enhanced immersion without compromising the ride's gentle profile. This approach drew brief influence from Arrow's earlier collaborations on themed transport attractions, adapting scenic rail experiences to coaster formats. Mine train coasters proved highly scalable for various park sizes, ranging from compact loops suitable for smaller venues to extended multi-helix circuits in larger installations, with Arrow building over a dozen examples across the by the 1970s. Capacity was a key focus, achieved through operations supporting multiple trains—typically three or four per ride—allowing throughput of up to 2,000 riders per hour in models like the Runaway Mine Train. Safety features included nylon-coated wheels on the tubular tracks for reduced and , anti-rollover guide wheels to prevent on curves, and manual lap bars for secure restraint, alongside synchronized dispatching systems using block brakes to maintain safe intervals between trains. These elements established mine trains as reliable, high-volume family attractions, influencing subsequent designs in the industry.

Looping Coaster Mechanisms

Arrow Development pioneered inversion technologies in the 1970s, introducing the model as the first modern to feature safe, upside-down elements. Debuting at in 1975 and followed by an installation at [Cedar Point](/page/Cedar Point) in 1976, the Corkscrew utilized two (and later three) helical corkscrew rolls, marking a significant advancement in rider thrill while prioritizing safety through innovative track and train design. These inversions twisted riders 360 degrees around the track's longitudinal axis, enabled by Arrow's tubular steel construction that allowed for precise curvature without compromising structural integrity. To ensure stability during inversions, Arrow employed upstop wheels—positioned beneath the rails in a U-shaped configuration—that gripped the from below, providing consistent contact and preventing even when riders were inverted. This wheel assembly, combined with side guide wheels and road wheels, distributed forces effectively, maintaining train alignment through high-speed twists. For energy management, Arrow integrated hydraulic braking systems on later looping designs, which dissipated through fluid resistance, allowing controlled deceleration and precise train spacing on multi-element layouts. Central to these mechanisms were physics-based considerations for vertical loops, particularly in Arrow's subsequent Custom Looping Coasters introduced in 1977. Clothoid loop shapes—teardrop profiles with a gradually decreasing from bottom to top—were key to sustaining positive G-forces throughout the inversion, avoiding the discomfort of abrupt transitions in circular loops. At the loop's apex, the minimum speed v must satisfy the condition where just equals gravitational force, given by v = \sqrt{rg}, with r as the at the top and g as (approximately 9.8 m/s²); speeds below this risk loss of contact, while clothoid ensures the train enters with sufficient (typically 20-25 m/s) to maintain at least 0.3-0.5 g downward. Building on the Corkscrew's success, Arrow expanded to multi-element looping coasters, exemplified by at in 1978, which featured the world's first pair of interlocking vertical clothoid loops. This design amplified thrill by threading loops in close proximity, with trains reaching 60 mph and enduring forces up to 4.5 g, while the upstop wheels and hydraulic trims ensured safe passage through the synchronized inversions.

Notable Installations

Attractions at Disney Parks

Arrow Development played a pivotal role in creating several landmark attractions for , blending engineering innovations with immersive storytelling to enhance guest experiences in themed environments. These rides, developed in close collaboration with , utilized custom mechanisms to simulate dynamic movements and narratives drawn from beloved films and , setting standards for immersion in theme parks. The , opened on June 14, 1959, at , introduced the world's first tubular track, enabling smoother, faster bobsled simulations through a 1/100-scale replica of the mountain. Riders in multi-person bobsled vehicles navigated dual intertwining tracks, encountering steep drops, dark caverns, and a dramatic encounter that heightened the alpine adventure theme inspired by Disney's live-action film . This attraction not only revolutionized coaster design but also integrated seamlessly with Disneyland's and borders, drawing over 1 million riders in its first year. Dumbo the Flying Elephant, debuting on July 17, 1955, at , employed a rotating arm mechanism with individual elephant cars that guests could control to rise and fall, creating the illusion of vertical flight. Themed around the animated film , the ride's 10 fiberglass elephants circled a central hub beneath a big-top tent, evoking the atmosphere with whimsical music and colorful decor to delight young audiences. Arrow's design emphasized gentle, repeatable motion for accessibility, making it one of Disneyland's opening-day staples and a symbol of joyful, interactive fantasy. The , also launched in 1955 at , featured a miniature pulling circus-themed cars along elevated and ground-level tracks through . Drawing from the film, the ride showcased detailed miniature villages and canals below, with the train's whistle and narration proclaiming its determination to deliver the circus, fostering a sense of nostalgic adventure. Arrow engineered the 2-foot narrow-gauge system with internal combustion power for reliable operation, integrating it into Fantasyland's fairy-tale landscape to provide scenic, family-oriented transport. For The Haunted Mansion, opened in 1969 at Disneyland, Arrow supplied the Omnimover system—a continuous chain of swiveling "Doom Buggy" vehicles that rotated to face pre-show scenes and ghostly effects in a sprawling New Orleans Square mansion. This dark ride vehicle technology allowed for precise pacing through 999 haunting inhabitants and illusions, enhancing the theme of spectral mischief with synchronized audio-animatronics and special effects. The Omnimover's enclosed design contributed to the attraction's eerie intimacy, making it a cornerstone of Disney's supernatural storytelling. The boat , installed in 1966 at after its 1964-1965 New York World's Fair debut, utilized Arrow's guided channel system to propel small boats through a global tour of singing animatronic children promoting peace and unity. Themed with vibrant international scenes and the iconic song, the gentle water ride's propulsion relied on underwater jets and chutes for smooth navigation, immersing riders in a message of cultural harmony. Arrow's engineering ensured reliable flow for high-capacity operation, solidifying its status as a perennial icon.

Rides at Other Amusement Parks

Arrow Development expanded its influence beyond Disney parks by designing and manufacturing a variety of attractions for other major amusement parks, demonstrating the company's versatility in creating thrilling and family-oriented that emphasized capacity and excitement. These projects, often tailored to regional themes and park layouts, helped establish Arrow as a key player in the growing theme park industry during the and , with installations that prioritized innovative effects and smooth-running mechanisms for high-throughput operations. One of Arrow Development's landmark non-Disney contributions was the , known as El Aserradero, installed at in 1963. This pioneering splash ride featured a themed course simulating a sawmill journey, culminating in a significant drop that created a dramatic water splash, marking the world's first modern attraction and setting the standard for future water-based rides with its use of individual log vehicles on a controlled path. The ride's design allowed for multiple smaller drops leading to a final elevation change of approximately 30 feet, accommodating families while delivering mild thrills through water effects. In 1974, Arrow Development delivered the Runaway Mine Train to , a family coaster that opened just days after the park's debut and remains its oldest operating . This themed mine train ride incorporated elements with scenic tunnels and Western motifs, featuring a single 65-foot followed by a 39-foot drop reaching speeds of 38 mph over a 2,428-foot track, providing accessible thrills suitable for a broad audience while evoking the excitement of a runaway ore cart adventure. The coaster's layout emphasized gentle pacing with helix turns and airtime hills, enhancing its appeal as an entry-level thrill ride in a park focused on diverse entertainment. Arrow's innovation in looping technology shone with the at , which debuted in 1976 as the first with three inversions: a vertical loop alongside double corkscrew elements. This steel coaster, spanning 2,050 feet with a 85-foot lift, propelled riders through three inversions at speeds up to 40 mph, pushing the boundaries of thrill rides by combining Arrow's tubular steel track with precise engineering to ensure rider comfort during inversions. The attraction's success highlighted Arrow's ability to deliver high-impact elements that boosted park attendance and influenced subsequent coaster designs across the industry. By the early 1970s, similar Arrow flumes like Stanley Falls at Busch Gardens Tampa in 1973, which operated until its permanent closure on September 7, 2025, further exemplified this approach, with dual drops and lush landscaping to enhance family engagement. Arrow Development's non-Disney rides underscored the company's global reach, with these installations influencing park operators worldwide and paving the way for successors like Arrow Dynamics to maintain and upgrade such attractions into the 21st century.

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