We were there last week as well and did not get to meet Flynn but the cast member told us he was "in and out". As far as the line, it can get quite long. When we were there, Rapunzel arrived at 11:00, we were in line by 10:15 and still had about a 15 minute wait after she got there. The thing about getting there early is you don't run a chance of having to wait in line while she goes off to take a break. 
Good Luck!
Good Luck!
