1. AA/RAC European cover.
2.No. Unless you plan to visit some of the minor Balkan countries, in which case you can get insurance at the border. But check your own first. Maybe health insurance. Be aware that some countries you will need a vigette if you plan to use motorways.
3. At five weeks, pretty much any route you want.
4. What makes you think its NOT safe?
5. Pass, cant help on that one.
You did'nt mention anything about accomodation? Hotels or camping?
The only downside, teenagers. God help you 
Just go and enjoy.
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