Ride Envelope and Track Testing Begins at Big Thunder Mountain Railroad Refurbishment in Magic Kingdom

May 17, 2025 in "Big Thunder Mountain Railroad"

Gallery / 3 Photos
Big Thunder Mountain Refurbishment - May 17, 2025

Posted: Saturday May 17, 2025 1:55pm ET by WDWMAGIC Staff

Another key milestone has been reach this in the ongoing refurbishment of Big Thunder Mountain Railroad at Magic Kingdom, as ride envelope testing got underway this week. Crews placed a ride envelope testing vehicle onto the track, along with a bright yellow test chassis, to begin evaluating clearance and safety tolerances along the newly installed sections of track.

Big Thunder Mountain Refurbishment - May 17, 2025

Photos by @DCBaker

What Is Ride Envelope Testing?

Ride envelope testing is a critical step in the refurbishment process of any major attraction. The test vehicle—seen in the photo below—features rigid fins extending outward from its frame. These simulate the maximum reach of riders, ensuring that no part of the surrounding environment, rockwork, props, or structures falls within unsafe proximity to the ride path.

Big Thunder Mountain Refurbishment - May 17, 2025

This process allows engineers to verify that all new track sections meet required clearance standards before further construction and theming are completed.

Yellow Test Chassis Spotted on the Track

In addition to the ride envelope vehicle, a yellow steel test chassis was also positioned on the track. These chassis units are typically used to assess weight loads, track alignment, and ride dynamics. Its presence today suggests that the retracked portions of Big Thunder are now entering the testing and verification phase of the refurbishment.

Big Thunder Mountain Refurbishment - May 17, 2025

Refurbishment Progress So Far

Since the attraction closed on January 6, 2025, significant work has been completed, including:

Full removal and replacement of track sections
Installation of a new lift hill
Ongoing work in the queue area, currently covered in construction tarps
Set installation work filed by both Icarus Exhibits and Mecca Productions
Multiple permits and Notices of Commencement extending into April 2026

The start of ride envelope testing is a clear sign that construction has reached a point where system validation and safety testing can begin. While this doesn’t indicate an imminent reopening, it does confirm that major structural work is nearing completion on key sections of the ride. Disney has said the ride will reopen in 2026, but has not given a more precise timeline.

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JohnD2 days ago

Here's an image from the DLR site for comparison.

wdwmagic2 days ago

Soem more pics of the new train https://www.wdwmagic.com/attractions/big-thunder-mountain-railroad/gallery/20jun2025-new-big-thunder-mountain-train-uncovered.htm

Coaster Lover2 days ago

Single bar that crosses the entire row. Same thing that was there prior to the refurbishment. I assume the padding will be added later (soon?). Honestly, unless they were forced to change the restraints (I've seen situations where rides with older restraints are grandfathered in from changing the restraints when new regulations come out, but would be required to change the restraint if they got new trains... that doesn't seem to be the case here) or changing the restraints would have permitted more riders (both more "fat" friendly and/or able to accommodate a lower height limit), there's really no other motive to make changes to the restraints. Single Bars on trains with no seat dividers with no seatbelts are by far the most efficient for loading/unloading. The moment you have a split lap bar you have to have cast members on each side of the train checking restraints. The current set-up allows ridiculous fast turnarounds keeping capacity as high as possible.

KatiebugFan2 days ago

If you can't wait for BTMR and want to ride something similar Hiccups Wing Glider at Epic Universe has the same vibe.

JohnD2 days ago

Enjoy that view while you can. You won't get to enjoy it for much longer.

danlb_20002 days ago

None of the pictures give a perfect view, but I think in this one you would see the split if it wasn't a single bar...

Smiley/OCD2 days ago

Works harder than Chappie EVER DID…and he didn’t raise prices on ANYTHING

Delta-73 days ago

The article claims that mud was deliberately plastered on the lower half of the train for "theming." I thought that was just from a rainstorm or something because in the first photos of the new train a few days ago, there was no mud.

Ayla3 days ago

Is it a single lap bar or is it like Splash Mountain's used to be (each person had their own). It is impossible to tell by the pictures.

gerarar3 days ago

More pictures of the uncovered BTMR trains from BlogMickey. Also seems to confirm visually that single lap bars are in place. Source and more pics:

solidyne3 days ago

Decent shot of the train. You realize, though, that the rest of this video is going to get eaten alive around here. You're throwing poor Nathaniel to the lions.

iamgroot613 days ago

I agree. I'm from Cali and recall the ride being much smoother (which, IMO, took away from the "mine train" aspect as I sort of liked the rougher, herky-jerky ride) after the refurb. On the plus side, I am really looking forward to seeing the FX updates in the ride climax in the last incline up inside of the "mountain." The WDW version of this ride really needed to catch up. Glad it's being done.