LEGOLAND Florida Rebuilds Iconic Coastersaurus Wooden Coaster With Modern Safety Upgrades for 30 More Years

Cory Lytle is the Tech Services Director at LEGOLAND® Florida Resort, bringing more than 25 years of experience in engineering, maintenance, industrial automation, project management, and organizational leadership. He joined LEGOLAND® Florida Resort in February 2025 after holding leadership roles with Sazerac, Morgan Foods and Florida’s Natural. Cory holds a Bachelor of Science in Electrical Engineering from Rose-Hulman Institute of Technology and has led major facility development and expansion projects throughout his career. 

What key factors drove the decision to fully rebuild Coastersaurus rather than replace it with a modern steel attraction?

Coastersaurus is a truly unique attraction as Florida’s only fully wooden roller coaster. As wooden coasters become increasingly rare, we saw an opportunity to preserve an experience that has been part of LEGOLAND Florida Resort for years while ensuring it can continue delighting families for decades to come.

Rather than replacing it with a steel coaster, we chose to reinvest in what makes Coastersaurus special. The rebuild preserves the authentic character of the ride while incorporating modern improvements that enhance safety, reliability and ride comfort for today’s guests.

What engineering and modern safety enhancements were integrated to ensure a smoother ride while maintaining its classic wooden feel?

The goal of the rebuild was to preserve the unmistakable experience of a wooden coaster while modernizing the attraction where it matters most. The project focused on improving safety, reliability and ride comfort without changing the character guests love.

The scope included replacing all structural timber throughout the ride, upgrading the operational control system and installing premium, heat-treated pine for the coaster’s posts, chords, diagonals, ribbons and bracing. We also added an updated programmable logic controller (PLC) with a touchscreen interface, a CCTV camera system for full track visibility, an upgraded magnetic braking system for smoother station stops and an advanced lap-bar monitoring system to confirm restraints are secured before dispatch.

How do you approach the long-term structural maintenance required to extend a wooden coaster’s operational lifespan by 20 to 30 years?

Wooden coasters require proactive maintenance because they experience natural wear over time. This rebuild represents a significant investment in Coastersaurus’ future and is expected to extend its lifespan by another 20 to 30 years.

The structural lumber has been treated with a wood preservative to provide long-term protection against rot and termites. Our team conducts daily inspections of the entire coaster, completing routine maintenance and repairs as needed. Because Coastersaurus operates outdoors in Central Florida, weather monitoring systems and lightning protection are also important parts of protecting the structure.

How does LEGOLAND Florida strike the right balance between preserving nostalgic, classic attractions and investing in brand-new experiences?

Our goal is to create experiences that bring families together, whether they are discovering something new or revisiting a favorite attraction. While new experiences keep the Resort fresh, preserving iconic attractions like Coastersaurus is equally meaningful when they continue creating memories for generations of guests.

Rebuilding the coaster shows that innovation is not always about starting over. Sometimes it means thoughtfully updating a beloved attraction so families can enjoy it for years to come.

From an engineering standpoint, what distinct tactile and sensory elements make wooden coasters so uniquely memorable for multigenerational families?

Wooden coasters offer a ride experience that is difficult to replicate. The natural movement of the track, distinctive sounds and unique feel of the wooden structure create a sense of nostalgia that connects generations.

Unlike steel coasters, which are designed for a smoother and more precise experience, wooden coasters provide natural movement, vibrations and airtime that create the feeling of a classic runaway adventure. For many adults, wooden coasters were their first thrill ride experience, and preserving Coastersaurus allows them to share that same feeling with their children and create new memories together.

Coastersaurus, Florida’s only fully wooden roller coaster at LEGOLAND Florida Resort, is being rebuilt rather than replaced with a modern steel attraction to preserve its distinctive character while extending its future. Cory Lytle, Tech Services Director at LEGOLAND Florida Resort, explained that the project is designed to maintain the coaster’s nostalgic experience while delivering modern improvements in safety, reliability and ride comfort. The rebuild includes replacing all structural timber and installing premium, heat-treated pine across the coaster’s posts, chords, diagonals, ribbons and bracing. Engineers have also introduced an upgraded programmable logic controller (PLC) with a touchscreen interface, a CCTV camera system for enhanced track visibility, an upgraded magnetic braking system for smoother station stops and advanced lap-bar monitoring to confirm restraints are secured before dispatch. The extensive work is expected to extend Coastersaurus’ operational lifespan by 20 to 30 years, with structural lumber treated against rot and termites. Daily inspections, routine maintenance, weather monitoring and lightning protection will support its long-term operation in Central Florida. According to Lytle, preserving the attraction demonstrates that innovation does not always mean starting over. Its natural movement, distinctive sounds, vibrations and airtime create a classic wooden-coaster experience that can connect generations, allowing parents to share a nostalgic thrill with their children while creating new family memories.