the express pass cost depends on the day of the week you are going and the date. the lowest amount can be $15 pp and then up higher. it is not always $40 a person as the set price for the e.p.
i always tell people to be at the parking garage before 8. wait until the garage opens and be one of the first to enter and park.
be at the turnstile by 8:15. the park will open around 8:25ish if there are many in line. not all rides will be open at that time as the park officially opens at 9 but there will be rides open at 8:30. you will get a head start in the park then.
eat at off times. the main crowds eat at noon and 6ish. eat at 11 am and 4ish and you will not have crowds. when the main crowds take time out to eat, you will have less people in line for the rides.
people that stay on site at the hotels or in the off site hotels near the park, generally leave the park in the early afternoon. they go back to their rooms to relax or take in pool time. this lessens crowds some days.
i suggest you go early to the park and do everything you can before crowds start forming around 11ish in the morning.
if the lines are long in the afternoon and the waits are up to an hour, then decide if you want to buy the express passes. why buy them if you have hit most of the rides you wanted to do. if there are only 3 or 4 more rides you want to do, wait in the lines then. you can only use the express pass once per ride or attraction. you can not repeat the rides with the e. p.
in july, the parks stay open to 10 pm.
if you are close to hitting all the rides you planned on, take the afternoon slow and you will finish up the parks.
you will not need to use the passes in the morning if you go early.
also, the passes are sold per park. if you have the studios e.p. it is not valid for anything at IOA.
if you are going during the 4th of july, lines will be everywhere.
if you have more questions please post again.