"We’re talking even 6 characters or longer, some upper and lower case, and maybe toss in a digit and special character."
6 characters? for 256-bit AES? That seems woefully inadequate. Imagine, say, 72 possible characters (52 a-Z, 10 digits, 10 special characters). This gives a password length for "full" 256-bit security as at least 128*log(2)/log(72) = 42 characters. If I'm wrong about this, please someone correct me! Either way, "6 or longer" seems far too short. Have I missed something here?
As for this particular person's predicament:
I, too, have been in this situation. I couldn't recite my password to someone; I can only touch-type it. It's a bizarre situation to be in and I've very nearly forgotten it myself in the past. I find it's easier to stop trying in case you accidentally "overwrite" your muscle memory and just go back to it later. Most recently, it happened due to my keyboard being detected incorrectly on boot and it almost drove me mad until I realised it wasn't my own error but the keyboard. I suspect if I hadn't have realised I might've been in the same situation as the OP.
In any case, Apple's implementation of FileVault is closed-source (to my knowledge) so it should always be assumed that someone who wants access to your data badly enough can get at it. I don't think it's worth being this paranoid about (e.g. the OP storing passwords as flat-files in a 256-bit AES encrypted disk image instead of just using the system keychain which manages all that for you).
Edit: I did find this interesting:
"The reason it’s so slow is because your AES256-encrypted DMG uses 250,000 rounds of PBKDF2-HMAC-SHA-1 to generate the encryption key. The ludicrous round count makes it extremely computationally expensive, slowing down the HMAC-SHA1 process by a factor of 250,000."
It doesn't seem so ludicrous if it works. Does anyone know if this is standard behaviour for encrypted DMGs?