Just as an update, after a bloody amazing trip, Star Tours was awesome and my 5yo adored it (as did I
) He got to do Jedi training and fought Darth Vader, which I suspect he will remember when he's got grandchildren!
Top tips I would pass on - don't plan Fast passes for too early in the day. Be at the entrance to the MK 45 mins before it opens and then head straight to whichever ride you really want once the rope drops. We got straight into Peter Pan, Mine Train and Space Mountain on different days with minimal wait.
If you're aiming for Jedi training at HS, the park opened for people to queue for that a good 50 mins early. If we'd not arrived at HS until it opened there's no way we'd have got into the academy. We then used the rest of the time before the rides opened to queue to meet Chewbacca 
The first boat from Fort Wilderness to the MK isn't until 8.30, which is useless if you want to be there early and run to a busy ride as soon as the rope drops, but if you get a boat to the Contemporary (which run from 6.45 or so) you can walk 5 mins along to the MK or catch the monorail.
The Memory Maker really is a nice little extra - we got loads of really lovely photos grandparent presents for years to come
And they are not joking when they say you may get soaked on the Kali River Rapids in the AK... One person per raft gets drenched... I could not have been wetter if they'd just thrown a barrel of water over me. Fortunately the weather was warm but that would have been wretched on a cool day.