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I have done that before, but not in one day. I would say minimum 1 night in Hatyai before going back.
A bus from Phuket Town to Hat Yai is cheap, go to Sadao border and do your stamp, stay one night in hat Yai and then take a bus back next day.
One way is maybe 7-8 hours.
If you need to go to Penang from Hatyai, its maybe a 4 hour ride.
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