The backtracking is a concern of mine, I'm having a really hard time figuring out my plan to avoid some of this? Like I said we're active people so the walking is okay for us, but at the same time I don't want to feel like we're walking back and fourth all day.
We want to do Kali at the end of the day specifically because we don't want to walk around wet all day.
I think if you are getting there at 8, you might be able to swap around a bit to avoid some backtracking. How about:
RD - Safari (finish around 8:40)
Pangani Trail (finish around 9:10)
Rafiki Planet Watch (return ~10:30)
Flights of Wonder (10:45 show, finish ~11:15)
Maharajah Jungle Trek (finish about 11:40)
Lunch (~1.5 hr break)
Safari again (FP #1) (finish ~1:30)
FOLK 2 PM show (FP #2) (finish ~2:30)
Discover Trails
Tough to be a Bug
Fossil Fun Games
TriceraTop Spin
Boneyard
DinoLand Dance-a-palooza
Finding Nemo Musical 4:00 show
EE (child swap or single rider line)
Kali (FP #3)
Oasis Exhibits
Now you are making a slow circle around the top of the park before lunch (you didn't say where you were planning on eating), you've got a re-set at lunch. After lunch, you pick up again in Africa but this time when working towards the right half you go through Discovery Island and catch TTBAB as you pass into Dinoland. This gives you about 1.5 hours after FOLK to make the 4PM Nemo, but you've also got a bunch of stuff in there that is very variable timed or you can cut if it just doesn't look that interesting.
I know that I put in time for Rafiki when you didn't respond to my earlier comment (so it may not be that interesting to you), but the issue is that otherwise, you've got a what-next problem after you finish Pangani @ 9:10. There is stuff to do in Africa like the drumming station etc., and you could pick up a quick snack and hang out until FOLK @10. Once you've done that though, you are committed to a backtrack for the second safari when that is the ONLY thing in the area you'll be doing, unless you do it right away. If you did that, then the first part would look like:
RD - Safari (finish around 8:40)
Pangani Trail (finish around 9:10)
FOLK 10 AM (no FP)
Safari 10:45 (FP #1)
Snack
Flights of Wonder @ 11:45 (finish around 12:15)
Maharajah Jungle Trek (finish around 12:45)
Lunch (~ 1.5 hr break, finish around 2:15)
Discover Trails
Tough to be a Bug
Fossil Fun Games
TriceraTop Spin
Boneyard
DinoLand Dance-a-palooza
Finding Nemo Musical 4:00 show
EE (child swap or single rider line)
Kali (FP #3)
Oasis Exhibits
The second half is very similar in both plans, includign the "start" time on Discovery trails. The big differences overall between the two (IMO) are
1) The first plan has early lunch and the second one late lunch (which you had in your earlier plan)
2) The second plan loses some of the oomph of the second safari as it is only 3 hours later and not morning / afternoon -- but I still think you would find it quite different
3) The second plan includes a lot of swing time between the first few stops; you'd spend this looking around in Africa etc. In the first plan, that loose time is concentrated into Rafiki.