I went to the cast Q&A on Saturday and the Expo on Sunday.
The cast Q&A was good - interesting that it wasn't in Toon Lagoon Amphitheater this year (not sure if it was last year, since 2014 was the last time I went). But it seemed like Toon Lagoon was a better place for it, as it seemed to have a better capacity, and there were actual seats.
It was indeed very crowded, esp. around the Music Plaza Stage (where the Q&A was held). DBF and I chose to stand in the back, on the sidewalk near Monsters Cafe. It was decent enough for me, as I could still see the jumbo screens.
I had never been to the Expo before. On Sunday afternoon (around 1:20), it was posted as a 120-minute wait to get inside (30 minute wait for vacation package holders - also 90 minutes for the sorting hat ceremony, which you could get a glimpse of while you were waiting in the queue for the Expo).
We actually got into the Expo in less than an hour. It was very crowded inside, and as
@Eckert said, there was another line inside a part of the Expo, which was for the WB Studio Tour HP Exhibition. We chose not to wait in line for that, as we had time constraints.
DBF and I are strongly considering getting the vacation package for next year. I wish we could get some sort of "a la carte" option for locals who are passholders, as we won't need the hotel portion. We shall see.