On April 18, 2004, Dan was racing on the Expert Cross Country at Sea Otter Classic. He had a good start until he got to the first single track downhill section. He crashed badly and landed on his face. He cracked his helmet, injured his face (as shown at picture), elbow, and lost two front teeth.

    After he was treated by the medic, he continued racing and finished the first lap. However, he broke his chain at the beginning of second lap Fire Road Climb. Finally, he called it quits.