You would just have to apply for another Thailand pass before returning to Thailand. (assuming they've not dropped the requirement by July). It's a pretty easy process now. Definitely not difficult enough to consider cancelling your Vietnam trip. And yes, you'll get another 30 day visa exempt stamp on your return
Yes, your visa and entry stamp are different. Print off the e-visa if you wish but don't believe it's 100% necessary. Your details are in their system and you'll get 60 day stamp on arrival, assuming you travel on the same passport that was on your visa application obviously
if this is one is currently on offer and he's being given it does it really effect you in any way? It's obviously the cheapest and easiest currently on offer
Ages in advance but if you're unvaccinated you'll need to upload PCR test result taken 72 hours before departure, so a bit shorter for that due to obvious reasons (although I believe you can still start the rest of the process before that and update it when you have the result, however the only other thing needed to upload, other than vaccine status is insurance proof so you won't be saving much time).
How many covid exstensions did you have? If you've been here for quite a while and then do an immediate bounce they may well be suspicious of your reasons for being here. An onward ticket and proof of decent funds would be wise