In 2014 we purchased and began using a John Deere Gator with Camoplast tracks to handle the bulk of our ski trail grooming. It also pulls our trail mower through 22 miles of rough trails during the summer.

As a result of a couple major breakdowns involving the Camoplast tracks, we’ve learned to carefully monitor the tightness of the bolt/washer combination that secures the hub bearings and holds the entire track on the Gator axle. Every 50 hours we perform a safety check on the tightness of the 12 mm diameter hub bearing bolts that hold everything together. If we discover a bolt is starting to loosen up, we replace it. However, on two occasions the bolt itself snapped off - requiring a delicate welding operation to mount a nut on the bolt shaft so the bolt could be removed. This happened most recently just one week ago.

The Camoplast tracks that we use are realistically designed for recreational use. However, we demand a lot more of the tracks when pulling heavy grooming implements up hills, down hills, across hills, over bumps and ridges. Even though we’re using new bolts and washers when they need replacement, they still have difficulty withstanding the abuse.

After one of these bolts broke off a week ago, we called Camoplast in Canada and spoke with a very helpful engineering technician. He knew that ski trail groomers in Europe had greatly diminished their problems with bolt breakage through one specific modification of the setup: they substitute a much thicker washer. This makes a lot of sense. We’ve noticed all along that the original washers tend to deform (cup) within the first 100 hours of use - probably allowing the bolt to loosen, perhaps allowing too much play at a point where the mechanical forces are extreme.

So this past week, we tried finding a thicker heavy duty washer by calling Fastenal, and by scouring the internet, and by speaking with representatives from several big online companies that specialize in selling fasteners. Nobody could provide what we were looking for!

Then an AHA! moment. How about trying the machine shop located 3 miles from our trailhead?

CPH Enterprises Inc said “Of course! - WE CAN DO.” They took the original washer, recommended an improved fitment for the bolt, and later that day provided a bid for fabricating the washers we needed. We gave the go ahead, and actually had the opportunity to watch the machining in action.

They used a Waterjet Machine to cut the new thick heavy duty washers. After programming the specs, it cut the washers using water pressure of 50,000 PSI. I’ve never seen anything like it, truly amazing!

Think Global, shop Local.  

The following pictures and video tell the story.

‍

Most of December 2020 was dry and warm. Instead of skiing the Blue Hills Trail, we’ve been hiking its ski and snowshoe trails. A recent return to colder weather allowed nearby lakes to freeze solid, and during the middle of the month we enjoyed skiing a 1-inch coating of snow on always beautiful Audie Lake (located 2 miles northwest of our trailhead).

Then the weather forecast got us all excited, calling for snow a couple days prior to Christmas. We started closing off traffic on the ski trails, hoping to retain the little snow already on the ground. However, December 23rd was warm with too much rain; toward evening the winds began howling, temps plummeted, and wind whipped snow blew on by. The following day temps were in the single digits and when we inspected the trails, we were pleasantly surprised to find about 2.5”-3” of new snow stuck to the ski trails. Just enough to start some early season grooming.

After several days of grooming, today (December 27th) we're enjoying very good skating and good striding on 'Excelsior Road' (West Side) and the 'Gravel Road' (East Side of the trail system). The rest of the trails have a thin base with an irregular surface, grassy patches and dirt spots - skiable but not nearly as much fun as the two 'roads'. Take a look at the maps (images below) for a quick summary of the open trails.

Here's what groomers have accomplished since the rain/wind/snow event of December 23rd:

• Packed (rolled) 'Excelsior Road' (West Side) and the 'Gravel Road' (East Side) on December 24th
• Packed (rolled) many of the East and West trails December 25th
• Packed (rolled) more of the East Side trails the morning of December 26th
• Brought out our big G2 implements (finishing tools) and groomed 'Excelsior Road' (West Side) and the 'Gravel Road' (East Side) the afternoon of December 26th. This included setting a shallow classic track.

Here's an inside view of our grooming logic:

• At the beginning of the ski season, the initial grooming is targeted at knocking the air out of snow next to the ground so the interface can freeze into a protective layer and allow frost to penetrate. If it’s cold enough and dry enough we use rollers for this first step. During that first step, we often discover damp areas that need to be compressed so they freeze up.
• As soon as the base is thick enough, out come the finishing implements (we use Tidd Tech Generation 2 groomers) to start sculpting the surface. We start setting classic track only after the base has set up AND when the base is thick enough to minimize exposing grass, dirt and rocks.
• On our trail system, we have a couple of gravel road surfaces that tend to freeze up and hold snow earlier than the rest of the trails. That's where you'll find the best skiing right now (look at the maps below).
• So much of the good skiing in the days ahead is dependent on the summer/fall trail maintenance. This includes mowing, bulldozing to deal with erosion, repair of bridges & culverts, chainsaw work to clear downed trees, and brushing the trail margins. Please join us when we put out the word seeking volunteers (we have an annual work day late September). 

Our head groomer put in an 8-hour day yesterday, and was willing to return late evening to touch up some trails. We told him to rest up, enjoy family, and wait for some fresh snow. No grooming today.

Ski the Hills!

Winter 2019-20 started early.

10+ inches of heavy snow November 27, 7+ inches of heavy snow November 30, 4+ inches of dense snow December 9, 2.5 inches of light snow December 12. Groomers had their hands full throughout December. This made for very good skiing over the Christmas and New Year Holidays. January added 14" of snow in generally light snow falls. February was dry, only 5" of snow. We had only one major rain event (1.5" of rain December 28), and the rain was absorbed into the abundant base. Trails were in great shape at Birkie time. Then warm weather moved in a week after the Birkie. The last grooming was March 13, but we were able to enjoy decent skiing into the beginning of April. All thanks to the big snows in late November.

We groomed a total of 57 times this past winter. Here’s the breakdown: once in November, 18 times in December, 19 times in January, 16 times in February, and 3 times in March.

Our head groomer and his crew were very willing to use our rollers - both of our rollers were used more this past winter than at any time in the past. As a result, this past winter the trails were groomed wider, and the edges were more firm. Groomers were very willing to try different techniques, and performed far more evening grooming than at any time in the past. This allowed the grooming to set up by the time skiers arrived in the morning. The classic track was in generally good shape most of the winter - the groomers were responsive to input from some of our most enthusiastic classic skiers. Thank you groomers!

The ABR compaction drag (we call it the 'Blue Thing') also was used more frequently this past winter. It was especially helpful removing high spots in the center of the trail, and when the trails needed a quick light touch-up of the skate lane.

Logging along Rut Road kept us from grooming that part of the East Side Core Loop the entire winter. Toward the end of that logging operation, it also disrupted our access to the West Side using the usual East-West crossover trail. However, one of the real pluses this past winter was the newly permitted use of Excelsior Road on the West Side for grooming and skiing. In the middle of December, after the gun deer hunts were done, a berm was plowed to block off traffic at the east end of Excelsior Road. We then groomed the entire 3 km length of Excelsior Road, and skiers were uniformly thrilled with the results.

Overall, it was a fairly long winter with very good skiing and snowshoeing in the Blue Hills. We hope the following photos trigger some good memories.

Skiers February 12th enjoyed wonderful conditions. Following the arrival of 2" of fresh snow on February 9th, our head groomer worked the evenings of February 9/10/11 and created some of the finest grooming of the winter. Firm trails, wide flat skate lane with corduroy that was often seamless across the skate deck, and a solid classic track with great pole plants. The photos with this message were taken February 12th on the West Side trails.

Next grooming is anticipated either Friday evening (Feb.14) or Saturday morning - probably touching up the most heavily skied trails so Saturday's skiers will be able to enjoy primo conditions.

First things first: packed powder conditions, skiing is great, especially in the classic track set this past weekend; and on the skate deck where touch up grooming was performed Tuesday evening (January 28th). Don't let the East Side logging operation scare you away. We are currently grooming 17 km of trails on the East Side, 9.6 km on the West Side. As an example, if you ski all the trails on the West Side, it'll add up to 14 km by the time you're done.

Snow Rollers, a pretty amazing natural phenomenon. We noticed one while skiing the Hemlock Canyon trail on Wednesday the 29th.

Here's our latest 'Gator Tale'. A true example of rolling with the punches...

• A few days ago we performed scheduled maintenance on our Gator. Oil change, check fluids, lube the Camoplast tracks, and check tightness of the hub bolts that secure the bearings and hold the tracks in place.
• Three of the four hub bearing bolts were a bit loose (that's why we check them). We removed and replaced two bolts.
• Shockingly, when removing the third bolt it snapped off. Now what??? (photos below show a partially removed bolt and washer on the left; snapped off bolt is shown on the right).
• We had access to the tools needed to extract the broken bolt. But we decided to enlist the help of a professional machinist from CPH Enterprises on County Hwy O, located just 3 miles away. With a bit of begging, one of their pros came out to the trailhead to help us out.
• These bolts are held in place using red Loctite. Removal of the broken bolt required drilling a hole in the center of the bolt, inserting an extractor (a special tool), and repeatedly heating the bolt with a torch while trying to extract it. The heat helps loosen the Loctite.
• After many attempts, the broken bolt seemed to move slightly - but at that point the extractor snapped off. Another 'Now What???' moment. Those might not have been the exact words we used.
• Next step? We were stuck. Late afternoon on Tuesday. Next step would require the use of a generator to weld a nut on the end of the broken bolt and use that nut to back out the bolt. This was set up for Wednesday morning.
• When cautiously trying to move the Gator from the shed to the parking lot on Wednesday morning, the bearing mechanism on the right rear track started shifting - which meant the entire hub assembly and track could fall off - with possible serious mechanical damage to various components.
• The crew of two that was working on the Gator on Wednesday was able to use several ratchet straps to secure the Camoplast track enough that it was moved to the parking lot.
• A nut was welded onto the end of the broken bolt; then with difficulty, the bolt was removed and replaced with new parts.
• The last challenge? Prior to the welding operation, the Gator battery needed to be disconnected by removing the positive lead. When doing that, the battery terminal broke off (a bit rusted). This meant a trip to Ladysmith to buy a new battery terminal (connector), then returning to the trailhead to repair the positive battery lead and tuck the Gator in the shed.

All set for some Friday evening grooming of the skate lane if all goes as planned. Should be a great weekend in the Hills!

A reminder....
When you're out enjoying a groomed ski trail, give special thanks to the groomers and volunteers that are so integral to cross country skiing on groomed trails.

Big snowfalls (10+ inches on November 27, 7+ inches on December 1, 4+ inches December 9) have kept our groomers busy. Early December hasn't provided this type of wintry weather in recent memory. Groomers worked 66 man-hours wrestling the heavy snow into shape for the weekend of December 7/8 when conditions ranged from fair-good-excellent.

A couple news worthy items...

• WE NOW ARE GROOMING EXCELSIOR ROAD up to and well beyond Letter A on the West Side. There's great skiing available out to the end of Excelsior Road, 3 km in one direction if you start at the Firelane Road. Either park along Firelane Road (well to the side of potential logging traffic), or at the warming house. Please do NOT try to drive on Excelsior Road up to Letter A, that's where we plan on grooming. Look at the modified West Side map (below) to better understand this change.
• If the beginning of Excelsior Road is rutted (hunters may be driving there until the gun deer hunts are completed December 15), you can enjoy the West Side trails by starting at the warming house on the East Side and skiing the trail that crosses from East to West at Letter L. Or you can park at Letter L - just be sure to leave plenty of room for logging trucks.
• Loggers have been working on the northwest part of the East Side this fall - along Rut Road in the vicinity of intersections 20-21-22 and Hemlock Canyon Trail between 21 & A - avoid this area until they're done. Images below include an East Side map that shows trails that are groomed, and how to avoid the logging activity.

Picture(s) with this message were taken the first week of December.

A gorgeous day in the Hills! What a nice way to cap off our winter. This morning's grooming began at 5:30 with the temps around 15 degrees F. By the time skiers started arriving at 8 a.m. the East Side Core Loop had a nicely scratched up sugar snow surface that gave great edge control on the rocket fast trails. Thrilling!

At 10 a.m. an enthusiastic group of volunteers pitched in to make quick work of tucking the grooming implements into their summer lodging (our 40-foot shipping container). It went like this:

• We mounted special wheels to our 8-foot Tidd Tech grooming implement, and it was backed into the shipping container with an assist from the Gator.
• We switched the wheels to our 9-foot Tidd Tech grooming implement and backed it in with the Gator getting credit for another assist. 
• Our blue trail compactor was moved into the shipping container using human power alone! 
• We placed our two rollers in the shipping container, and called it a wrap.

Let's not forget how really strange this roller coaster winter was. Here's a quick summary:

• The first part of the winter - up until February 5th - delivered very little snow, 4 separate meltdown events, 5 separate rain events, with a Polar Vortex thrown in for variety. Despite all that, we found enough snow to groom 13 times and periodically enjoyed some pretty good skiing. Audie Flowage served as a beautiful alternative to trail skiing.
• Then on February 5th the Snowmaggedon hit! I recorded about 53" of snow between February 5th and March 9th. (Click here to check out our snowfall summary since 1999.) To say the least, our groomers were challenged. They groomed 18 times in February, and 10 more times in March. Often it meant long hours spent grooming, frequently in bitter cold temps. In all the deep snow, I lost track of the number of times the groomers needed to use their front-end winches (and multiple lengths of tow straps) to pull themselves out of trouble.
• During the peak of the snowfalls, we were forced to deal with a couple of major equipment problems with our Gator. Taking the bull by the horns, we completed the repairs in the field ourselves - minimizing down time and keeping labor costs to a minimum.
• Last point, something definitely worth noting: as of this morning, the snow to the side of the trails has solidified like a rock. On mornings following an overnight freeze, crust skiing can carry you anywhere you want to go. Let your imagination be your guide.

Maple syrup time, Ski the Hills!

Some equipment information we think will interest you... On a warm day while grooming this past March, the Hyfax slides on our new snowmobile overheated and needed replacement. (The slides are a hard plastic material attached to the metal rail - positioned between the moving rubber track and the metal rail, they shield the metal rail from abrasion - however the slides can overheat if operating in 'dry' conditions).

We've never needed snow scratchers before, but realized this is a must adaptation to help kick up snow/ice and cool the slides when grooming on hardpack snow - i.e. 'dry' conditions. We purchased cable (reversible) snow scratchers locally and earlier this week - after a bit of trial and error - installed them on our Bearcat snowmobile (the scratcher tips are carbide & replaceable). Everything lined up nicely. It's easy to hook the scratchers on the rail when you need them out of the way. Preventing equipment problems keeps our ski trail groomers happy and on the go.

With that task completed, we decided to check the state of the snowmobile battery, drive belt, and driven belt sheaves. First we used our lever lift stand to elevate the Bearcat's rear end. After napping for 6 months, the 'Cat fired up on the 2nd turn of the key, purred like a kitten, then roared as the track turned a few revolutions quite nicely. We again disconnected the battery and put her back to sleep -- waiting for snow!

Lastly, a modification that was installed a couple weeks ago... During the grooming season, the Bearcat sleeps in a shipping container where ice tends to build up under its track. To make entry and exit less harrowing for the operator, we placed an eyebolt in the threshold; then created an easily removable setup where we can secure a piece of salvaged snowmobile track to the threshold so the 'Cat can get a good toe hold. The trails are in great shape, go take a hike!