Ever try to make something 3d appear to be there, and then not? It's a different beast than making something 2d appear/disappear. 2d can rely on lenticular, digital, etc. But 3d? Different. Especially when you are up close. And having to do it thousands of times a day. I believe it was supposed to be instantaneous. Not a gradual disappearing. And the hatbox wasn't supposed to be much bigger than his head. Admittedly you can use the back half of it to hide the head, but to make it appear pretty much out of thin air? Not so easy. Spinning head? Fiberoptics? Fancy lighting? Most of the low end parlor tricks used in the rest of the mansion really won't work in this setting, hence one of the reasons why it has been gone for so long.
The original effect was done purely with lighting and a special type of fluorescent paint. It worked in testing, but when installed in the attraction, his head on his shoulders didn't disappear completely due to all the ambient light in the attic scene. The head in the hatbox did work well, as the hatbox was made of scrim material, so when the light was out, you couldn't see it. The figure was also placed too closely to the Doombuggy track.
Both original figures were reported to have been dismantled. It was also reported by Al Lutz that the new figure(s) has/have already been built. The latest rumor prior to this was that they're planning on waiting until this new film comes out so they can make the figures look like the one in the upcoming film. Personally, I hope they just go with an exact replica of the Blaine Gibson head, and not worry about if the movie HBG looks a little different.
The other issue is what will happen to Chatty Connie? If she remains where she is, she will still be casting off quite a bit of ambient light, which may or may not impact the new HBG, depending on what technology is being used this time. They can't put her back in the original bride's position, unless they plan to move the piano. Also, Connie doesn't have the glowing, beating heart that is supposed to be synched with HBG. What will they do about that aspect? I hope the get rid of her altogether and restore the Attic back to the original, but I seriously doubt that will ever happen.
In any case, I just want him to come back. That was
the biggest disappointment when I finally got to go on the ride and there was no Hatbox Ghost as described in the original record album. (Well, that and the fact that the facade was completely different with no logical explanation. What did I know or care about theming way back when? I just wanted to go inside the Mansion that was shown on the album cover!)