I didn't witness it but several years ago I remember reading that a Pluto-ish CM fell off a float in the backstage area, was run over, and died. How sad is that? I imagine those large costumes and limited site/mobility can be quite dangerous. Also, considering the Florida heat, how the heck can they stand how hot it gets in there? I've often wondered what the trick was because you know they'd be dropping like flies in the dead of summer if they didn't have some cooling technique.
My sons are both 9+ so we don't really go seeking out the characters too much. Our character experiences come at our character meals.
Great thread, tho.