Firstly, thanks to all the others who have posted useful information in this thread. Having just successfully booked a couple of RTWs ex-KRT, I thought I would share my recent experience.

I created my itinerary using the online tool; note that if you try to end the itinerary somewhere other than KRT, it may give you a price more than double what you expect. This happens when you try to end in AMM and MCT, possibly others. Ending in AUH or DOH is fine and gives you the same price as ending in KRT. Also note that the open-jaw created by ending somewhere other than KRT, counts as a segment, so you end up with only 15 useable flights.

However, the online tool still fails (as it did last year - there's another thread on this) after inputting my credit card info. So I called the AA RTW office and read off my itinerary to them and told them that it would be ticketed in Canada and should be priced in Canadian Dollars. They then have to send it out for pricing, now done in Dallas since the tariff office in Dublin closed a few months ago; they say it usually takes one day, but it came back a few hours later. Surprisingly, their price, after converting to US$, was about US$200 less than what the online tool was quoting.

I then emailed the record locator and my credit card info to Naeem Thaver at Gala Travels in Ontario. A few hours later it was ticketed and he sent me a confirmation email, and of course you can view it on aa.com. Their fee is CAD75 + tax but it's well worth it for what you save. I booked a DONE4 starting in Khartoum in December this year, but I was so thrilled at the price (US$3512 incl all taxes and fees) that I decided to book an AONE3 to start at the end of the DONE4 in April 2013!

I did NOT try to do a less-than-6 hours turn at KRT in order to avoid getting a visa. Instead, I booked a flight from DXB on FlyDubai for US$122 one-way.
After all, if I'm going all the way to Khartoum, I might as well see a bit of the country. I contacted a travel agent in Khartoum who say they can arrange an "airport entry permit" which they will email to me to print out and show to the airline to allow me to land at KRT. At KRT there is apparently a special counter where you show the entry permit and you get a visa on arrival for a fee of US$150. And yes, the travel agent also charges US$150 to get the entry permit; not cheap for a visa, but better than the hassle of mailing your passport to a Sudanese embassy and waiting, and waiting, for a response.

I'll try to remember to report back at the end of the year, assuming it all works!

Another useful pointer when you have multiple flights on non-AA airlines, as you do with RTWs, is that if you ask AA (regular phone agents or RTW office) to email you the itinerary, it arrives in a different format from the regular ticketing email. This format includes the following additional info for each segment:
- the type of aircraft
- the flying time
- the terminal that the flight operates to/from
- the booking reference on partner carriers, if it is not the same as the AA Record Locator

This information is helpful so this is the document that I print and carry with me. However, note that it does NOT include the ticket number so you need to either make a note of it on this document, or carry the E-Ticket Confirmation email also.

Happy Travels.