, KL is known for a rather long processing time. You need to check with them. I think I saw the post about that Non-immigrant visa processing time in KL is a bit shorter than DTV/tourist visa, but I cannot assure.
, employer needs to prepare more documents for you to apply for an initial visa at the local immigration office than for the application to RTE/RTCG. Also, some employers don't meet the requirements for in-country initial visa procedures. That's why you need to talk with the employer and cannot choose on your own.
No minimum number of stay-out is specified to enter Thailand again. You may be able to enter Thailand on the same day you cancel your extension if you just return to Thailand.
BUT, if you apply for your new visa at the RTE/RTCG in another country, you will stay there until the visa is issued.
You seem to mix the procedures a bit. You will take one of these after you cancel the current extension, then leave within the cancellation stamp's validity.
1. Return to Thailand on a visa-exempt for a 60-day stamp. Then go to the local immigration office to apply for an initial Non-B visa.
OR
2. Apply for the initial Non-B visa to the RTE/RTCG during your stay in that country. You wait there until the Non-B visa is issued. Then will enter Thailand on a newly issued visa for a 90-day stamp.
You need to talk with your employer about which one you must follow. It's not your choice. It depends on the documents your employer prepared.
depending on what method op uses to meet financial requirements, but proving international transfers for funds could be an issue to apply for an in-country initial visa if he wants to use 800k baht banked money method.
If you will be back in Thailand AFTER the current entry or extension stamp expires, no, there is nothing you can do with it. Your visa/extension will be gone as of the day it expires, even if you have a re-entry permit.
In case you are staying INSIDE Thailand from the day it expires until applying for the next extension, you may be able to apply for an extension by paying an overstay fine if it's not too long. But not when you are outside Thailand when the stamp expires.
The easiest is applying for a new single-entry Non-O based on being over 50/retirement during your stay there before you fly back to Thailand, then apply for an extension when you are back in Thailand with a new Non-O for a 90-day entry stamp.
Yes, most likely, you cannot apply for a long-term in-country visa and/or yearly extension at the local immigration office inside Thailand until you cancel your existing extension, regardless of whether it's expired or not.
Go to the immigration office that issued that extension to cancel it next time you are in Thailand. You may also need to cancel your old work permit if it's not cancelled as well. You may or may not be fined (same rate as overstay fine, up to 20K baht) for not cancelling it properly, depending on when your extension based on employment expires.