Feed the Koi in the morning at DL Hotel.
Walk thru the paths by the waterfalls at DL Hotel.
Sit by the outdoor fireplace at the Grand in the early am and enjoy a hot chocolate (exit the lobby thru the doors near the big fireplace).
See the Golden Dreams show in DCA
Do the factory tours in DCA (bonus: free tortilla- yum!)
See the Seasons of the Vine show in DCA-- never a full crowd and it's kinda neat to watch how grapes become wine.
Watch the complete set of clips in Animation building.
Go to Toontown after the area is cleared for safety (after fireworks when the park is open until midnight). Very short line to see Mickey at his house- no line for Roger Rabbit ride.
Walk the stairs up to the Gallery.. I never knew about this on our first trips, now it's a must do!
Minimal wait for the show in the Opera House on Main St. -- the movie is interesting and it's cool to see the imagineering stuff.
Cool down in the air conditioned Main Street theater, very quiewt in there- I see people take naps on the dias stage in there LOL.
Sit on the porch on Main St and peole watch/eat icecream.
Listen to the party line phones in the coffee shop on Main Street.
Listen to the conversations from the windows by the lockers.. piano tutor and a dentist at work
Listen under the windows in New Orleasn Square- back by the bathrooms.
Play with the machines in the Penny Arcade- I love the band in the box!
Listen to the piano players at Coke Corner (share a chili footlong)
Have the kids make cookies -- fun and not many partcipate.
Children can take a pin trader class at the pin shop in TL (not sure if they still do this, my boys did it and recvd two free pins for trading).
Ride the train for a "grand circle tour"
Here's some more that may be "line less" experiences
http://www.thegoodgirls.com/small_memories.htm