I hope I can answer some of your questions..........
DH and I did
MNSSHP last year. In fact, we went on 10/31/01! It was one of my all-time favorite Disney experiences (and that's from a person who's been to Disney 10 times so far!).
If memory serves, MNSSHP started at 7:00. I made reservations for LTT for 5:45, so we made sure we entered the Magic Kingdom around 5:30. LTT was super crowded when we got there, so I was really glad I made my reservations a few months prior. We had plenty of time to eat without feeling rushed at all. The character interaction was terrific - - some of the best interaction I've ever experienced.
By the time we were done eating, we walked right into MNSSHP, which was in full swing. We wandered around a bit, looking at all the cool decorations and watching all the other guests in their costumes (BTW, I'd say that 95% of the people had costumes on). If you go, MAKE SURE YOU GET A GOOD SPOT FOR THE PARADE! DO NOT MISS the ride of the Headless Horseman! The parade is terrific. I think they had a special parade for kids (sorry, we don't have kids so I'm not 100% sure what that was like). They had tons of activities going on in Tomorrowland. I recall a huge stage set up & guests were dancing and having a great time. Also, they had a DJ booth set up in front of Pirates of the Caribbean and several characters hosting a "Halloween Dance Party". That was so much fun. The best part was when the DJ played that cheerleading song, "MICKEY" (Hey Mickey, you're so fine you blow my mind, Hey Mickey!). Minnie Mouse led everyone in a dance to that song (complete with pom-poms).
If you have any specific questions, I'll try to help.