In this episode of the Race Ready Podcast, Brian Halligan and Andy Newell sit down with legendary ski technician, physiologist, and mentor Zach Caldwell for a wide-ranging conversation that bridges the worlds of elite performance and real-world application. Zach dives deep into the evolving craft of ski preparation in the post-fluoro era, breaking down why methodology often matters more than brand choice, how film thickness and layering affect durability, and why meticulous scraping, brushing, and workflow discipline can completely change race outcomes. From testing iron temperatures at World Cups to analyzing cleaning layers and fleece tools, Zach explains how small technical details, executed correctly, produce big speed gains on snow.

The conversation then moves into Zach’s unique coaching philosophy, shaped by decades of working with athletes like Chris Freeman, Noah Hoffman, and countless developing juniors. He outlines his key training principles, including the idea of short response times to intensity, the importance of staying parasympathetic during high-volume base work, and why aerobic “economy” must come before big power outputs. Zach shares how heart-rate variability, breathing control, and recovery monitoring guide his approach to volume training, and why elite athletes must learn to train at true low intensity if they hope to build durable engines that respond quickly when speed is required.

Finally, Zach reflects on the human side of coaching, mentorship, technique, and long-term development. He explains how technique isn’t about angles or biomechanics alone, but about muscle state, blood flow, and efficiency, telling powerful stories about reworking Chris Freeman’s movement patterns to unlock late-race acceleration. He also discusses helping Freeman manage Type 1 diabetes while competing at the highest level, emphasizing that athlete relationships are built on trust, communication, and care as much as performance metrics. This episode captures the rare perspective of someone who has influenced the sport from both the waxing bench and the training track—and who believes the true legacy of coaching is the people shaped along the way.