Also, if you think big, you can have say 1,000 SF of walls then 500 SF of an open outdoor scene (indoors) then lather rinse repeat. Even tight passages cna be done with 60 panels per 1000 Sf costing in materials and paint about $30 each. So, New stuff $1800/1000 SF = $1.80 per SF. Then you can go lower than this by collecting surplus materials, buying used materials, finding alternative materials like old metal sheeting and what ever, being creative. You might infact have 1000 SF of dirt and a shovel? Even with the wiring harness, safety gear and semi trailer I might a little over $2 a SF. I have bought used walls and repainted them/ repaired them for as little as $10 each total. They have a history to them already.
you can build a real house for $40/SF but, No ceiling, no floors, no real doors, limited electric runs, no real utilities, no appliances, no pool, If you are planning a payroll, you only need limited amounts of props to start. Lots of flea market furniture and dumpster finds. What industrial finds you may overlook every day like giant saw blades that are no longer re bitable, barrels and drums, All available for scrap weight.
The most expensive part of a haunted house? Off season and build up storage. Pretty much any building material, or device can be found or donated. The storage may cost More than the haunt if not planned for ei go directly to semi trailers on land that does not have additional rent, do not pass go, do not collect $200. Other wise, in 5 years time you will have forked out $20,000 in storage and moving fees and the haunt was cleverly cobbled together for $3500 and it really couldn't be better for what is being done.
To me what is missing in all of your description is where you will be located, generally what town. Many towns just will not support $1000 per night payroll and $500 to charity per night. It just isn't going to happen so make other plans. If you crash 60 people a night using volunteers in some cases that is all there is going to be no matter how much you spent to advertise.
Yet, this isn't bad if it really is a Monster Museum. Hollywood may never find you if you are in a market that doesn't deserve the investment of a web site and any more than local advertising. It could be 100 well dressed mannequins and perhaps only two jump to life? Is it an academic town or where they have redneck games? Trying to get licensing is going to be denied.
Also, where you are might tip off someone who has one sitting in their yard that has no place to go and you could have it for free (no start up costs) or for so much per ticket? Some people already have 10 years of crap left over from themes not being displayed this year.
What would I do with the other $23 per SF? Donuts seem to be popular?
Another fabulous post from the U.S.Department of Wild Imaginings, now in spectaclar stereo, sponsored by the Adhesives and Sealants Council, suggesting ways to stick things together since the 1800s. Not fabulous in a gay way. Your results may vary. Illinois residents add 8% sales tax. These posts have been made by professional post makers, do not try this type of posting on your own without extensive training, lovely assistants and a trusty clown horn.