Thai Tourist visa in Kuala Lumpur

You can fly to Penang. Either Fire Fly or Air Asia go there.

From Phuket?

A number of solutions/ options have been offered but none will suffice and sure as day is light there are not an infinite number of options.

Yes from Phuket. Check their websites.

Interesting that AirAsia offer cheaper price for fly to KL if compare to Penang... but its closer )

Edit: its because no direct flight from Phuket to Peneng at AirAsia. Flight is through KL.

FireFly make better offer, but need to plan it at least 1 month before

So you didn't plan one months before and so have to pay the price. I'm on Samui and use firefly to Penang just to activate my next entry at a cost of around 6.5k return every three months. I do it for the food mostly.