A lot goes into planning, building, and testing a new roller coaster before guests can strap in. Take Millennium Force at Cedar Point, which guests got their first hint at on July 2, 1999 when the park registered a trademark on the name. Then a couple days later the Intamin designed track started appearing on-site.

You can see a detailed history and photos of the Millennium Force construction on our website.

After all the track has been installed, electronics and other systems are in place, the park conducts what is called a pull-through test. One of the ride vehicles is outfitted with a template that tries and simulates the farthest reach that a rider would be able to extend while riding the roller coaster and ensure all clearances are met.

In March 2000, Cedar Point placed the first train onto the track, the red Millennium Force cars.

However, the pull-through test on Millennium Force was conducted using the blue train. The wooden template was pulled through the roller coaster and was thought to have no clearance issues.

The first test run on Millennium Force with water dummies was conducted on March 30, 2000.

After an exhaustive construction schedule in the cold Lake Erie winter, Cedar Point opened Millennium Force to the media on May 11, 2000 and opened to the public on May 13.

It was only after Millennium Force opened that apparently some guests were hitting their hands on a support on the fifth support column of the overbank turn. As a result, the support was modified to add a notch to provide more clearance. You can read a pretty lengthy research on the Millennium Force column modification on Medium.com.

Most guests likely will never even see or know of the Millennium Force modification. The issue also shows the importance of a successful pull-through test to make sure guests have a safe and enjoyable ride experience.

* If you liked this post, join other readers who have signed up to for our free Newsletter…because then you will never miss another update!