The story of Disney’s The Twilight Zone: Tower of Terror attraction starts around 1985. A small team of Imagineers had been tasked with creating two new pavilions for EPCOT. Those plans included something called The Great Movie Ride. Newly appointed Disney CEO Michael Eisner liked the plans so much he decided that this new ride shouldn’t be in EPCOT, it should be part of a completely new park!

This new park would be a “studio back lot” themed park dedicated to Hollywood and entertainment.  And it wouldn’t just celebrate show business – it would help create it with real movie and TV production facilities on site.

Disney entered into a licensing agreement with Metro-Goldwyn-Mayer and branded the park Disney-MGM Studios. (This would later become a point of contention, and modern-day readers will note that the park is now named Hollywood Studios.)

Disney-MGM Studios opened in 1989.

But the park was pretty small, and some say it was rushed to open in order to compete with the brand new Universal Studios, Orlando, which opened almost a year later in 1990. To really stand on its own, MGM-Studios would need an E-ticket attraction – something amazing to draw the crowds. In 1989, movie director Mel Brooks, Disney CEO Michael Eisner, park designer Marty Skylar, Imagineer C. McNair Wilson and a group of Imagineers met to discuss plans for the park’s first expansion and first thrill ride.

Early Ideas and Designs

Numerous ideas were kicked around for the new park section. One early and prominent idea was a “Castle Young Frankenstein” attraction, complete with Bavarian village and drawbridge leading to the castle. This idea morphed into “Mel Brooks’ Hollywood Horror Hotel”. Early in the park’s development, Imagineer Bob Weiss had pursued the idea of an art-deco high end 1930’s-style hotel near the park’s entrance.

Mel Brooks left the project, but the idea of a spooky hotel had stuck. Disney’s team looked at available movie and TV licenses and found a perfect match: The Twilight Zone.

Technological Innovations

With Sunset Boulevard and the The Twilight Zone: Tower of Terror attraction idea in hand, Disney’s Imagineering team was ready for the next challenge: finding the technologies that would bring the attraction to life.

AGV Technology

Transitioning the elevator cars horizontally, from the back of the attraction to the front, via a corridor scene known as “The Fifth Dimension” was one engineering challenge. The elevator car would need to separate from its lift elevator and safely transition from one elevator “harness” to another. This tricky design challenge necessitated the refinement of a technology Disney had used before: the Autonomous Guided Vehicle.

The AGV is a self-guided passenger car capable of moving from one elevator (at the attraction’s back), through the 5th Dimension, and into the grand finale drop sequence elevator (at the attraction’s front), all on its own without any rails or tracks. The vehicle follows a pre-programmed path and communicates with the ride control system.

It’s an impressive technology, though not immune to breakdown as the occasional hat or park map dropped in the 5th Dimension has shown.

Elevator Technology

The world’s oldest and most famous elevator manufacturer, Otis Elevators, contributed to the design of the “free-falling” elevator.  Otis had spent over a century refining and downplaying the sensation of riding in an elevator, but Disney was asking it to play it up – and play into people’s worst fears about elevators. Fortunately, Otis signed on anyway and lent its expertise to the project.

Continue reading: Building the world’s first Tower of Terror