Great, just found flights out of Catania to Barcelona. We won't have to go to Pisa after all :)

I've added San Vito Lo Capo to our Itinerary.

Pookymimi this is a great itinerary. Do you have day trips planned to Erice and Segesta?
Have you found any great places to stay?

I believe we would to got Erice when we are in the area, we won't stay there though. At this point I see about 3 nights a place, my kids' minimal stay in a place.

Erice is easy to visit from Trapani.
Three nights for each place is minimal stay for me, too.

San Vito Lo Capo looks like a great place for your family's interests!

FWIW -- which may be nothing! -- I don't find seeing Sicily's highlights well suited to a plan that calls for 3-night-minimum stays. With 3-night-stays, you can, of course!, have a wonderfully memorable trip. BUT you might not be able to see all the things you want to see, unless you commit to some VERY long days trips. :-( So, as just one other thing to consider, you might consider separating for a night or two here and there, with those who don't want to move more frequently staying place and those who want to be able to visit particular sites (or visit them for longer times) moving on. Just an option to consider....

I am done with reservations, everything is subject to change if Itinerary isn't workable, but here it goes..

Ortygia --> Taormina--> Aeolian Islands --->
Agrigento --> (side-trip to Piazza Armerina for Villa Romana del Casale on the way to Agrigento or back to Cefalu where husband arrives to meet us) -->
Cefalu --> Palermo --> San Vito Lo Capo -->
Trapani(where we fly out to Barcelona)

sounds like a terrific trip - hope it all goes well.

You are really getting the best of Sicily in this trip. It seems a shame to have to travel from Aeolians to Agrigento then back to Cefalu, but that probably has something to do with timing for you.

I have tried to rework that but the only thing I can come up with is to go from Milazzo to Piazza Armerina by way of Catania, cutting west to Piazza Armerina, stay a night, then Agrigento, and back up to Cefalu. At least you will be doing a circle route with the least amount of miles overall.

This has probably been mentioned already, but be prepared that Agrigento is a wide open site with no shade, so it will be very hot. Early morning, or later afternoon might be best. It's also a very large area, so be sure to allow enough time to explore, along with the archaeological museum.

Have a great trip!

"It seems a shame to have to travel from Aeolians to Agrigento then back to Cefalu, but that probably has something to do with timing for you."

Sundried you are right, the only option would be for us to skip the South area with Agrigento, but I believe it's worth the 2 hrs train ride or car rental and back to Cefalu. As I've not been in the island before I don't know what's the easiest way, but per my books and Rio2Rome cutting through seems to be the fastest. I'm trying to do 3 nights on each place, 2 nights in a couple.