Maybe I'm a dork, but I love seeing the planning process for Halloween props as much as the final product. The preliminary sketches, schematics and notes... great insight into the process, and a testament to the care and commitment to doing things right.
These displays show what's possible with a little creativity and common supplies like fabric and foam. As always, I love those foam cutout props. After layering to create depth, and then painting, you almost can't even tell what they're made of. I always say I'm going to make some props with these material... maybe this will be the year.
With the size of your latest Halloween sign, I get that storage can become an issue. Have you tried any tricks to split them into smaller parts that you can puzzle-piece back together? You could use parts of the design to hide the seams. For example... maybe there's a spider hanging right at the center of the sign, and that spider's silk thread hides the split line where the halves connect.
Good job documenting the process, and final outcome in the photos and walk through video. I recognize a lot of your props that you made for past Halloweens. I bet that takes a little pressure off, as time goes on, because you have more objects that you can mix and match to fill the space.
Kudos to the wife and kids for their help in making this magic too. I love the idea of the old ghost family haunting the place. The photos with the transparency effect are fun (and spooky!). Real white contacts for the whole family? How did everyone like wearing those?
Also, I got a laugh out of the photo in the grocery store while in costume. I always try do that at some point. Even if I don't really need to buy anything, I'll run a couple errands before my Halloween party just so I can freak out shoppers and employees with my costume.