I've never been during April or May, but I've been in October once and September once - this fall will make that twice.
Crowds are low. We wait at the most 15-20 minutes. We do get fast passes because it's still possible to have waits as long as 45 minutes (especially for RnRC and ToT, two of our favorites). It's very doable... not many kids as most are in school. LOTS of little ones under 5 though.. be prepared for noisy buses on the way to the resorts if you're staying on property.
We love September and October traveling. We have also gone in March. Our trip in 2007 will be in April. How are those crowd levels?
Not sure if I'm allowed to post the site, but google "Touring Plans" and look at the best days.
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