Do I need a USPS return envelope for each member of the family? What about the $65 money order...is that for each passport request? Does it have to be a money order?

No. You can use one envelope for all your family members passport provided they are being sent to same address. You need to clarify the $65 own

The only question I can answer is that it must be a money order and it must be a money order obtained from the post office

Ade, thanks for all the advice. Any thoughts on why I haven't received the passports yet even after paying $65 To expedite on 10/31? I travel 11/14

Same return envelope can be used for all family members. The money order is for individual member of the family and can be obtained from anywhere, I got mine from the business center next to the consulate. The most important thing is to go early. All the best.