"Instead of driving from Lisbon to Porto in one shot, we stayed overnight at the castle. WOW! Living in the US it is not uncommon to spend over $200 for a fairly plain room in a generic hotel located next to a highway. Our room cost less than that and it was in a BEAUTIFUL castle, surrounded by a forest with hiking trails, with nice gardens, and incredible living rooms and porches. I had seen mixed reviews of the dinner online... my wife and I had dinner and breakfast at the castle and the food and service were great... among the best we had during our 10-day trip to Portugal.
It is about 2.5 hours from Lisbon, and about 1 hour from Porto. We arrived in Lisbon from the US, saw Lisbon for a few days, then took the train to Sintra. We rented our car in Sintra, and drove to the castle arriving around 5pm. Had a great time hanging in and around the castle, had a great dinner, and a great breakfast the next morning, and then headed off to Porto. So glad we did not visit a big city, and then do a long drive straight to another fairly big city. Bussaco Palace was the perfect place to pause in between Portugal's two big cities."