I think you will have to go through Bangkok to get to Penang. Try YWG-(YYC or YVR or ORD or SFO or LAX) - HNL -(NRT or ICN) - BKK - PEN. If you route through the US on United you can avoid surcharges, but might be tough to find that many tickets. I went the other way to KUL. (YYZ-FRA-BKK-KUL). That may be possible too, but you won't get a stop in Hawaii!

Also check here http://www.flyertalk.com/forum/air-c...ineraries.html Lots of good advice can be found there.