We *just* got back from celebrating my son's 7th birthday there. We spent 4 days in the parks (planned on 5 but ended up in Hooks pool instead LOL).
On his actual birthday we did Carnation Cafe (his choice) to make the PB&J sandwiches - they sang to him & brought him ice cream, then the Pat E Cake thing at 2pm at Plaza Inn (I was suprised that Mickey & Minnie came there). We did Celebration Roundup for dinner (he loves Woody, ribs & corn on the cob).
Other touches - at restaurants they always sang to him and brought him mini cupcakes or ice cream, at Rainforest he got the Volcano dessert - huge hit! You can go into City Hall and pick up the phone and Goofy sings happy bday to you. At the character meals, we were always given a bday card and they were signed by all the characters. We bought deluxe bday goodie bags at Goofy's ($10), and bought the pirate birthday bucket ($15).
We had a Disney cake delivered to the hotel room - came with matches & candles too). I decorated the room - balloons (we brought a mini helium tank), streamers, ribbons, and vinyl birthday banners I zip tied to the DLH bed posts.
We did the $59 gift card, and the whole trip he made his wish list, then at the end of the day on his actual birthday he got to spend it - he was in heaven. Then we went back to the room for cake & presents.
Ride the monorail - if they see the bday badge they might let you ride up front.
Tons of people said happy bday to him - he loved the attention. Get the bday name pin and the I'm Celebrating pin. We got balloons from the DLH too.
In CA if you go on the tortilla tour he'll get a bag of 12 tortillas.
In Build a Bear they gave him a birthday sticker and made a big fuss for him.
Oh on the Big Thunder (his fave ride) the CM saw that it was his actual bday (I had a special bday shirt made for him in addition to the Bday Mickey ears and pin LOL), and let him skip the line, and ride up front (his fave seat) - then my 4 year old proceeded to dart out and made the alarm go off and trains stop - bugger.
I can't think what else we did. I'm a big birthday celebrating person and tried to do all sorts of special little things for him.