Bedtime routine?

I'm thinking of reworking Nolan's (5) bedtime routine because his sleep habits have changed and I don't like them! He takes forever to get to sleep and then wakes up so darn early. It's killing me. He doesn't ever stay in his room and fall asleep until 10:30. I am putting him back to bed 3-4 times before he stays put and passes out. Then, he's up at like 5:30 am and comes in our room to announce that he is up. We send him back to his room, but he just plays and doesn't get any more sleep. He is at school from 8:30-3, so he can't take a nap, and he comes home exhausted and mean. He perks up around dinner time and the cycle starts all over again.

Right now his routine is dinner at 5:30, bath time at 6:00, storytime/prayers until 7, brush teeth, wash hands, get in bed at 7:30. Then he makes appearances randomly until 10:30 and whines in his bed that he's bored until finally falling asleep. It's frustrating because I know he's tired! He can hardly get through storytime without a complete, overly exhausted meltdown. 7 hours later he's back up to terrorize the house after I've been up twice in the night with a 7 month old. I'm slowly withering away.

On the weekends he sleeps until 8-9 am and takes a cat nap after lunch, and goes to bed at 7:30 with much fewer appearances throughout the night. So, I really just can't wrap my head around what his issue is. He doesn't complain about anything besides being bored when he isn't sleeping, and after school he is just in the worst mood ever and barely keeps his eyes open during his snack, but if I let him nap at 3:30 I'm afraid he'll never go to sleep!

Any advice? Anyone else dealing with this? I just don't know what to do anymore besides some serious discipline at bedtime.