Hi Gillian,
Your trip will be here before you know it! You've got the right idea...Mickey Ears are a must! I was just at The Chapeau a few days ago and they do, in fact, personalize the Mickey Ears there. Perhaps the machine was temporarily down when your friend was there? There are actually 4 shops in the Magic Kingdom that personalize the Mickey Ears, in addition to other places on Walt Disney World property:
Magic Kingdom:
Curtain Call Collectibles (Main Street, USA)
The Chapeau (Main Street, USA)
Fantasy Faire (Fantasyland)
Big Top Souvenirs (New Fantasyland)
Epcot:
Mousegear
Hollywood Studios:
Adrian and Edith's Head to Toe (Sunset Boulevard)
Downtown Disney:
Wonderful World of Memories (Marketplace side)
You can also order them from the
Disney Florist and have them delivered to your room.
Additionally, you can purchase them from the
Disney Store online and have them sent to your home before you leave.
I hope this helps and that you have a wonderful vacation filled with countless magical memories!
Please let me know if I can assist you further,
Kaylene