Does he have to bring the chair in lines or can it be left somewhere, like in stroller parking, if the line is short?Also, can he fold it up to bring it on the bus? He doesn't want to stay in it on the buses and take up the space that a full-time wheelchair user might need.
Wheelchairs can be parked in the stroller area, if he doesn't want to use it in line. There are some things in the disABILITIES FAQs thread that will be helpful to you. One link goes to
this thread about boarding rides for someone who might need more time. There are some things to think about with the rides that have moving walkways that are discussed on that thread.
The FAQs thread also has information about riding the buses with a wheelchair or ECV. A folded wheelchair can be brought on board, but many of the bus drivers will still want to put it in the wheelchair spot and tie it down (those wheelchairs are heavy). Even if you plan to fold it, it is easiest to still bring it thru the back door.
ETA: Also, if you have any tips for the wheelchair pusher that would be great. None of us have ever had to push a chair before and we're not sure how hard it's going to be to push my 6'4" brother around all day!
The main wheelchair pusher may want to get some gloves (the kind that serious bikers or weight lifters use). That helps protect against blisters.
If he is at all fit, he should be able to do some pushing himself, which will help too.
At MK, there is a large hill going downhill from Fantasyland toward the Haunted Mansion area, so it's best to go from Fantasyland to the HM, not the other way around.
In WS at Epcot, there is a hill that goes uphill from France toward the middle of the bridge leading to the UK. Then the hill goes downhill toward the UK.
Some of the hills are quite steep and you don't want to get the wheelchair going too fast - they can get away from you pretty quickly.
Regarding the parade areas and the lines, does my brother have to sit by himself in the parade area and go through the line alone in his chair, or can he bring someone with him? Can he bring more than just the pusher? We are a group of 7 (2 kids) so I don't expect that we can all go together with him.
That's kind of variable, depending on how busy it is. A 'usual' wheelchair party is considered to be 5 people plus the person using the wheelchair. With 2 kids, they would usually allow you all to stay (only one person over). But, if it's really busy, they may limit the number of people allowed in the wheelchair viewing area for parades.