A big problem with Expedition Everest is that the design of the mountain was ground-breaking, BUT that the budget was trimmed too much. If you look at the mountain structure, it is just barely big enough to accommodate the ride, and support struts for the mountain come close to the support struts for the roller-coaster and the Yeti.
The mountain part of the ride should have been designed with larger support struts, (look at the Golden Gate Bridge to see how massive pylons can really support a structure). If properly designed, it would have allowed access to the Yeti and its support structure, in the event that the creature would need a major repair. Yeah, this would have required more $ for steel, but at least the Yeti would have been serviceable.
The ‘backside’ of the mountain, plainly visible to guests from the parking lot, looks bad, even with the fix. Remember, imagineering was waiting to get the money to ‘fix’ this little problem when Everest just opened. A lot of the special effects planned for the ride were cut, like the part where the Yeti breathes on guests in the dark. (Think warm air blown at your neck that smells . . . meaty.)
I am not a structural engineer, but here is what I would do:
1. The Yeti is still cantilevered out, this will continued to crack the foundation with even the smallest movement. I would remove the Yeti, and replace it with a much lighter weight version which is centered on the cement foundation. The current Yeti is built like a car and weighs something like 20,000 pounds. You can build a Yeti which is approximately the same size, but weighs less. I would do it by having Garner Holt (or somebody else) build a relatively light weight super-sized Yeti fig out of PVC, then onto this I would spray something, some sort of polymer, which would be use to create ‘hair’. Good-bye tons of fur-coats. I would ‘animate’ this figure by using a pulley-system, to let the creature turn its head, and move its arms, making the Yeti a big puppet. At the speed guests go, the ‘wires’ wouldn’t be seen.
2. I would add other special effects, such as the Yeti breath!
3. I would extend the ride by adding a ‘cave’ section, which would allow for guests to see either the Yeti again, or effects of the Yeti’s passage.
If you want to get creative, you could produce a similarly scary effect. The old Yeti was greet because its ability to “lunge” at you, i.e. horizontal and vertical movement, was one of a kind, but there are other ways to thrill guests too.