I mentioned the pump in my first response because I know of folks who can simply turn theirs off entirely when exercising and this does help simplify the problem of dropping too low when doing strenuous exercise. However, that doesn't mean that a pump is a cure-all. I personally do not use a pump, and maintain a barely-above-non-diabetic a1c level that has not wavered at all since I started my current insulin regimen of Lantus and Novolog. So this is my personal preference -- in my case a pump cannot improve control since control is optimal right now with insulin injections. But the reality is that the Lantus is working 24 hours per day after injection and you can't completely turn that off like you can a pump.
Glucose tablets may indeed be a wonderful solution for long exercise, partly because you can carry lots of them with you without having lots of baggage. That's my primary problem with Gatorade (which also absorbs very quickly) -- you have to carry it with you.
The other thing that I have heard is good is Honey packets - like from the restaurants - they are small and easy to carry and high sugar as well.
Kevin, the pump is suggested because it's the most effective way to deal with issues like this. It also helps improve control overall. But you're right, it isn't for everyone, and people won't know until they check it out.
Why is everyone's response to tell people to go on the pump? This is not a solution just a preference. If you like it great but if not that doesn't help.
I too have to take in lots of carbs before I work out. The only trick that seems to work for me is to take Glucose tablets or Glucose gel. These have the sugar but not as many calories that go with the food you need to take for the same result. I have to bump my levels up about 150 bp to be able to work out. That is a HUGE amount of calories. Glucose tablets go in and are used up during the workout because they are so fast acting. By the end of the workout my levels are normal. These are available at any pharmacy or drug store and are very cheap. And they are precisely measured. Usually Tablets are 4g/tablet and Gel is 15g/tube.
I know of other type 1 diabetics who do strenuous exercise using the pump. These folks simply turn off their pumps while exercising to avoid lows. If using shots, you can't do that, but you may need to lower your pre-workout insulin levels some. My twin's doctor recommends sports drink such as Gatorade for active diabetics because it replenishes more than just carbs and it is absorbed into the body quicker than juice alone, so you might think about switching from juice to sports drink. It is obvious that you are burning those carbs and need them, so I would think that you may need to lower insulin before exercise so less insulin is working on those carbs.
Are you on the pump?
If not, you might want to consider switching to the pump. It gives you much more accurate insulin dosages which is known to prevent low blood sugars.
The pump has plenty of problems as well. What does your endo recommend?