We went Phuket to Penang last year, and found there were no direct flights. As has been suggested, via KL is probably quickest, although Tiger via Singapore might be cheapest by Air. We ended up catching the VIP bus from Phuket town to Hat Yai, then a Minibus to Penang. Very cheap, but its about 10hours total driving, and VIP bus gets in late to Hat Yai, so means an overnight.
Crusty, what's Penang like busy wise at the Thai Consul? I've just done a KL run. Got to the Embassy 8.45...about 30 already in front of me...gates open 9.30...I got out just before 10.30. Pickup next morning got there 10.30...they stuck strictly to the 11.00 handout and got away about 11.15 so not too bad.
But what's waiting times like at Penang? I can imagine it's not so busy there?
The main reason I spent 2000 Baht extra on flights is that in Penang you don't have to go in person.
My hotel clerk did it for me.The money changers in Chulia street also do the service for a fee of 30 Rgt.You just fill in the form and give them your passport,money and photos.They take it in the morning and you get it back the next afternoon.
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