The Ultimate was designed by Big Country Motioneering (BCM) and the park's original owner, Robert Staveley. Construction began in early 1990, taking 18 months to complete. The ride's Canadian redwood trestles and large station building were constructed by Staveley's in-house construction team, which was responsible for building Lightwater Valley's other buildings. The metal track work was ordered from BCM who used fabricators 'Tubular Engineering' to manufacture it. However, much of the installation was largely undertaken in-house and supervised by engineers from British Rail after BCM were sacked due to track problems and slow progress. The scale of the project led to both contracted companies going bankrupt halfway through its construction, leaving Staveley's team and British Rail to finish the project on their own. Staveley got assistance from American and German roller coaster manufacturers, who advised him to ensure that there was enough flexibility in the track to allow for expansion and contraction under fluctuating temperatures. Overall, the project was over a year behind schedule and went significantly over budget. Staveley wanted to ensure that he was the first to ride his creation well in advance of its opening in order to give himself time to improve and re-work areas of track. He did so by riding in one of the trains that had not yet been fitted with any restraints, using only rope to secure himself.