Mystery of Haunted Mansion's Hatbox Ghost solved

But then stories emerged from reputable sources, as did a handful of grainy photos. Theories, and entire websites, were woven from this phantom's appearances in historical documents and memorabilia.

Now the myth-turned-legend has come home, rejoining his 998 spirit companions in Disneyland's Haunted Mansion.

The Hatbox Ghost has risen from dead technology to become a featured attraction of one of the park's most popular rides.

Not bad for a specter that was more spectacle than spectacular.

Ray Spencer, one of the Disney Imagineers responsible for reanimating the spirit, wasn't around when the Hatbox Ghost was unceremoniously yanked from the attic shortly after the attraction opened in August 1969.

But Spencer was well aware of the stories, because the Hatbox Ghost has haunted the halls of Walt Disney Imagineering far more than any other Mansion phantom.

"Just about everyone knew about the Hatbox Ghost," Spencer said. "But there really wasn't much of an appetite to reinvent or reinvigorate it."

Its "vanishing head" effect originally was crafted by the legendary Imagineer Yale Gracey, known for his creative yet simple effects, Spencer said.

The Hatbox Ghost, dressed in top hat and cape and leaning unsteadily on a cane, was so named by what he held in his right hand. He stood out for his meticulous and formal outfit, and for his ghoulish visage that made him look dangerous, if not a bit hungry for passing souls.

The "gag," as Imagineers often call special effects, was that the ghost's head would disappear and quickly reappear in the hatbox.

The Gracey-designed trick relied on lighting and perfect timing, Spencer said. The head glowed under black lights, "disappearing" when the light turned off. A split-second later, light illuminated the hatbox, revealing the head.

It worked well in off-mansion tests, and pleased Imagineers placed the Hatbox Ghost in the attic, not far from the ghostly bride.

Unfortunately, the Hatbox Ghost proved more real than ethereal.

"They didn't account for the ambient light inside the attraction," Spencer said. "The figure was placed so close to the track, you could still see the head when it 'disappeared.' "

The Hatbox Ghost went to a better place, if you consider disassembly a better place. The ghost disappeared so quickly that the few who saw him began to wonder if it had been an illusion.

As years passed, the Hatbox Ghost became as much a part of Haunted Mansion lore as tales of spectral visitors rubbing elbows with their animatronic counterparts.

Which is why Spencer was so happy when he was asked about 18 months ago to return the Hatbox Ghost to its happy haunting ground.

"First of all, the character is very iconic," he said. "He's seen on T-shirts, figurines, prints, posters. He stands alone as a great design himself."

Spencer also embraced the challenge posed by fans who have spent years gathering Hatbox facts, rumors and innuendo. No simple animatronic figure would do. The Imagineer knew the ghost's return would be analyzed from every direction.

Spencer had two things going for him: a past sculpture and present technology.

Several molds had been taken of the ghoulish face sculpted decades ago, the visage still popping up around the mansion. And with the latest lighting and projection techniques, Spencer and his colleagues found a way to make the illusion work.

Still, it took months of research, mock-ups and, most importantly, secrecy. He knew fans would spirit away the surprise if they found out what he was working on.

"I didn't even let my family know what I was doing," Spencer said. "For us, this was a really big deal. For fans, it was a huge deal."

Imagineers feared discovery even as they installed the Hatbox Ghost behind a black wall erected for secrecy. Not wanting to shut down the Haunted Mansion for the sake of one character — even one as legendary as Hatbox — experienced riders no doubt noticed the blank space.

Working among 999 grim or grinning ghosts, Spencer's biggest fear wasn't the dark, but the light.

"I worried constantly we were going to be found out," he said. "There was a lot of speculation, but we were never discovered."

The biggest challenge in resurrecting a revered revenant was making sure the technology did not overwhelm the charm. The Hatbox Ghost couldn't go from wraith to riches overnight.

Spencer was accustomed to such challenges, facing them each time Imagineers "plus" an attraction.

"It's a game we frequently play," he said. "The Hatbox Ghost was built in 1969. If we exploit technology, it's visible to guests and no longer part of the time frame. Making the tech invisible is very important."

The Hatbox Ghost officially was unveiled May 9, just as Disneyland prepared for its 60th anniversary. The ghost was not an official part of the celebration, though Spencer appreciated the timing.

The phantom's appearance offers one more reason to celebrate the park's tomb, er, milestone.

"This was much bigger than simply installing another animatronic figure," he said. "Not just to us personally, but to our guests and hard-core fans. We put a lot of emphasis and pressure on ourselves to really deliver."

The Hatbox Ghost dwells near the point he stood for a few days in August 1969. Take away the special effects and the top-hatted, cape-wearing phantom hunched over a cane may well have been there all along.

At least in spirit.

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