J.P.
It starts to cool some here in October but I still wouldn’t make anything too heavy. You also can't make something exactly like the characters because Disney WILL make you change (this is more for adults). They really don’t like adults going around looking too much like their characters because if they are mean or bad people it will be a reflection on Disney. There were two incidents this year with Disney officials having people change and/or leave the parks.
The only time Disney characters dress up is at the Mickey’s Not So Scary Halloween Party in the Magic Kingdom, this will cost extra to go but it is worth it. There are usually no lines for the rides (not all the rides will be open) and they will have character meet and greets with some that are not usually out. They also have trick or treating in the park.
If you choose to go don’t go on a Friday night, that’s when all the locals go and it gets really crowded.
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Here are the links from this year, this is for adults and teens not young children.
http://wreg.com/2012/06/05/teen-told-to-leave-disney-park...
http://www.foxnews.com/us/2012/07/25/christmas-in-july-sa...