The Chessington Winter Workshop Tours offer a rare and fascinating glimpse behind the scenes of one of the UK’s most beloved theme parks. Designed as an exclusive three-hour walking experience, the tour invites guests into the engineering heart of Chessington World of Adventures, revealing the expertise, planning and dedication required to keep its headline attractions operating safely and efficiently.
From the outset, it is clear that this is no ordinary backstage visit. Led by Martin, a long-serving member of the Merlin team whose experience dates back to before 2000, the tour is rich in technical insight and historical perspective. His depth of knowledge and passion for the park’s rides elevate the experience far beyond a simple workshop walkthrough.
Introduction and Safety
The day begins with a comprehensive safety briefing delivered by Martin. Guests are instructed to remain within clearly marked green pathway areas at all times, reinforcing the operational nature of the spaces being explored. This emphasis on safety immediately sets the tone: these are active engineering environments, not staged exhibits.
Photography is restricted in certain areas, a reminder of the technical sensitivity of some systems. Nevertheless, these limitations do not detract from the overall enjoyment; if anything, they enhance the sense of exclusivity.
Spare Parts and Engineering Support
One of the first revelations is the scale of Chessington’s parts storage operation. The park holds over £1 million worth of spare components, all meticulously catalogued and managed via a computerised inventory system. Every item removed is logged, and once stock reaches a predetermined minimum threshold, the system automatically reorders replacements.
The parts store itself is organised by ride. Vampire alone occupies four full racks, housing everything from individual bolts to full seats and wheel assemblies. Other attractions such as Tomb Blaster, The Gruffalo River Ride Adventure and Sea Storm each have their own designated shelving. The scale of preparedness is impressive and highlights the proactive approach taken towards maintenance.
During the closed season, additional roles are created specifically to support the engineering team. These temporary positions focus on cleaning, inspecting and refurbishing rides across the resort, demonstrating the extensive off-season effort that guests rarely consider.
Engineering Main Workshop Tour
The main rides workshop is divided into three primary sections dedicated to Vampire, Dragon’s Fury and Rattlesnake. Interestingly, the area now used for Rattlesnake components once housed the trains for Scorpion Express.
The workshop itself is exceptionally well equipped. Engineers have access to a wide array of specialist tools for cleaning and inspecting ride vehicles, alongside a built-in overhead crane capable of lifting up to five tonnes. This crane enables heavy components to be transported safely across the workspace.
Rattlesnake operates with eight cars in total but runs only five at any given time. Two are prepared and ready in the workshop, while one remains as a strategic spare. Dragon’s Fury similarly owns more cars than the ride system can operate simultaneously, ensuring that maintenance can occur without affecting overall availability.
Once ride trains are fully certified, that certification remains valid for twelve months, reflecting the stringent inspection and approval processes in place.
Tiger Rock Workshop
Tiger Rock presents a particularly interesting case study in water ride engineering. The attraction technically features three lift hill segments: the initial lift and drop, followed by a second lift divided into two separate sections powered by two motors and two drive belts.
Adjacent to the station lies a two-floor maintenance workshop shared with nearby rides such as KOBRA. This space stores essential components and provides direct access for technical intervention.
Within the station, a drive belt keeps boats moving steadily. The motor at the front of the station connects to the roller via a coupling system. Because the motor and roller use separate shafts, engineers can replace the motor independently without dismantling the entire station belt assembly — a clever design that minimises downtime.
The original control panel remains inside the operator’s cabin, disconnected but intact, with suggestions it may appear at auction in the future.
Although water is usually pumped back into the flume by this stage of the closed season, ongoing lift hill work has delayed that process this year. Each winter, belts and rollers are removed for inspection and replacement where necessary.
An additional interesting detail about Tiger Rock is that the wheels fitted to the boats are only engaged when the boats descend the drops, helping to guide and stabilise them during these high-speed sections of the ride.
The boats themselves require relatively modest maintenance, largely focused on wheel and pin checks. They are fitted with anti-rollback devices designed not merely for lift stoppages but specifically to prevent backwards movement should a belt failure occur.
Mandrill Mayhem Workshop
As the newest rollercoaster in the park’s line-up, Mandrill Mayhem represents a different generation of engineering sophistication. Its dedicated workshop contains everything required for maintenance, from replacement wheels to specialist wheel-cleaning equipment.
The launch system is particularly intricate. Air holes within pipework help cool the launch fins, while smaller fins act as speed sensors during Launch 2 and within the station. These sensors inform the control system of the train’s speed and direction. If installed incorrectly, the system would interpret the train as travelling the wrong way and automatically enter safety mode.
Each seat is secured by two independent hydraulic cylinders. During daily operation, the control system conducts alternating Test A and Test B checks to verify restraint security.
Mandrill Mayhem features second-generation vest restraints, which remain unlocked upon leaving the station thanks to additional train-mounted components. The technology mirrors the mechanism used in automated car boot systems.
Because the ride lacks a transfer track and trains remain on the circuit overnight, wheels may temporarily develop flat spots. During the first run of the day, a distinctive sound can sometimes be heard, though the wheels gradually regain their shape as they warm.
Notably, this is the first Bolliger & Mabillard rollercoaster equipped with retractable contact connections linking trains to the control system. These retract during launches to prevent damage, as do the station’s drive wheels, which disengage to protect drive tyres.
A removable track section near the front of the station allows engineers to access the pit below for wheel inspection and replacement. Launch 2 connects to the ride’s central control hub via fibre optic cables located beside the maintenance building.
When wheel re-lamination is required, they must be shipped to California. For efficiency, this process is undertaken only when necessary and typically in large batches.
Vampire Workshop
Vampire, one of Chessington’s most iconic attractions, was undergoing winter maintenance during the visit. The ride will operate with two trains for the 2026 season, with the third train stored in the main workshop.
At the time of the tour, one train had already been reassembled and returned to the track. The second was partially rebuilt, with its leading rows suspended in place while remaining seats awaited installation on pallets nearby. Seeing the train as bare metal framework — without seats, restraints or even its lower guide wheel — offered a uniquely revealing perspective.
Although three trains exist, only two run simultaneously. Operationally, the ride performs more efficiently this way, as the third train historically caused delays by stopping on the second lift hill.
It is technically possible for two trains to occupy the station at once using a mid-station sensor, though this feature is currently disabled. An additional metal component at the rear of each train communicates position data to the control system as it passes key points.
Unlike many modern coasters that fail closed, Vampire’s brakes require air pressure to remain shut. At night, trains must be secured with ratchet straps when air pressure is absent. However, a non-return valve system and accumulators positioned above each brake section can sustain safe operation for up to three trains in the event of pressure loss.
Contrary to rumours, Vampire’s early closure for the 2025 season was not due to structural sinking.
The station’s airgates also rely entirely on air pressure and cannot be manually operated.
Exclusive Extras and Finale
Unexpectedly, the tour concluded with a quiz offering guests the chance to win authentic ride components, including Vampire brake fin sections and various bolts from across the park.
Exclusively for Winter Workshop participants, guests were also given the opportunity to purchase retired signage and ride parts. Items available included rollercoaster wheels from Mandrill Mayhem, Vampire and Rattlesnake, a computer from Dragon’s Fury, a 2025 park map and even a vest restraint from Mandrill Mayhem.
Final Thoughts
The Chessington Winter Workshop Tour is an exceptional behind-the-scenes experience that showcases the extraordinary level of engineering required to operate a modern theme park. It combines technical depth with engaging storytelling, largely thanks to Martin and the knowledgeable guest speakers.
Far from diminishing the magic, seeing the inner workings enhances appreciation for the precision, safety systems and dedication involved. The scale of spare parts management, the complexity of launch technology, and the meticulous winter refurbishment programmes all underline the professionalism of the engineering team.
This was an unforgettable experience and one we would eagerly welcome back — perhaps with new areas opened for exploration in future editions. Vampire, Mandrill Mayhem, Tiger Rock and the wider engineering department have never felt more impressive.
For enthusiasts and curious guests alike, this tour offers something truly special.
