After extensive looking through my books and materials, I can quote the following "Facts" about the monorail, which was the original intention of the post:
-The max capacity for the current Mark VI monorail train is 372 people.
-The trains run at various intervals, but about 5 minutes between trains is average, yield approximately 4,500 passengers per hour per train.
-There are typically 2 or 3 trains running on each loop (there are 3 loops) at a time during busy times of year. This yields an average capacity per loop of about 11,000-12,000 passengers per hour (lots of rounding here). There is at most two staff assigned to each monorail.
-Buses hold approximately 55 people (we've all been on some with more), and run every 15-20 minutes, with a complete loop taking close to 30 minutes for a bus. However, with approximately 374 buses available for service, the hourly capacity of the buses is a whopping 40,000 passengers per hour, but requiring 374 staff driving and an additional 10-20 staff to deal with routing buses to next locations.
-There are no costs directly tied to monorail in any of Disney's public reports. Those costs are buried in transportation, attraction and hotel costs (portions of monorail costs are in all 3 portions of their accounting policies).
-Construction cost in 1971 was $1 million per mile. Recent monorail projects in Las Vegas and Brazil (both licensed Disney technology and trains) ran closer to $100 million per mile on average. Disney doesn't have some of the same issues that these two places would, but it is safe to guess that the cost is well over $1 million per mile. Inflation alone would have the cost now at $6 million per mile, and that is probably grossly under cost.
-If you guess, and say that the cost is only $25 million per mile, and 2 loops around the property just to resorts would run around 50 miles, your cost is $1.25 billion, plus operations. At approximately $350,000 per bus, you would have to buy 3,500 buses to break even on the up front costs. Operations will save you some money.
As I look at those numbers, if those costs are for real, then the construction cost would have to come down by a factor of 10 to make it even a little bit worth considering. Disney just doesn't replace buses often enough to justify that cost differential. I hate that I am saying it, but I don't think it makes sense to expand the monorail on the property, much less to the airport and back from a purely financial perspective.
Would it be REALLY cool? Yes. Unless those construction costs can be lowered it just won't happen.
Dang. I really love the monorail.