Where are you now in Thailand?
In reading your post, you appear to be experienced Visa/Border runners. (Suggest you read Tod Daniels post recently made)
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After this, is there a better way for you to come to Thailand to avoid the necessity for entries as visa exempt and border runs?
Such as the METV multiple entry tourist visa obtained from your home country? With planning you can get up to 9 months stay with simple border bounces.
The METV is among other Visa opportunities.
Good luck with your KL or Penang plans. We look forward to hearing back from you. Thank You.