Disclaimer: We were there when this section of Broadway was under construction. The layout before/after construction may be different.
We strolled up around 7:30ish and the outside studio was already full of fans. There was a short line of about 15 people or so which was supposedly to get into the main area. The outside studio itself is only about 50 feet long and they put about three people deep in there. Even though a few people left the main area as we stood there, security never moved people around to allow more in. Therefore I would get there around 6 if this is really important to you.
If you just want to check it out, there is plenty to see as you're walking by. Security won't let you stand or loiter and will constantly be telling everyone to keep walking but I took enough trips through that I got a couple decent pictures of Ginger doing the weather outside and of Josh, George, and Robin inside the studio. You could also try standing across the street at Toys R Us.
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