Thank goodness I finally got all the resorts planned out. (You guys helped me more than you will ever know!)
Now I have to plan my way to spring the surprise on DH.
Here's what I thought of:
May 10: travel, check into Pop Century, dinner at 'Ohana
May 11: Magic Kingdom, dinner at Chef Mickey's or LTT
May 12: Studios & Epcot
May 13 (ANNIVERSARY DAY! 
): check out of PC early, head to Animal Kingdom at open. Spend a few hours there...then casually "suggest" we head over to AKL to check it out and get some lunch.
Get to AKL, explore, get some lunch, then walk up to the front desk to "ask them a question" and proudly announce we're checking in!
DH will never see it coming!
I'm most concerned about the anniversary surprise at AKL. I may end up just telling him we're spending the rest of the week at POFQ, I don't know. Do you think that "surprise plan" will work?