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Hi Danny. The RTNETLINK answers: File exists error means that the network wifi files are still in place. The script has to clear them before the hotspot can be started. If it will be permissions again if that can't be cleared. If your already connected to the network then that response is fine.
the error "Failed to connect to non-global ctrl_ifname: (nil) error:no such file or directory"
is again clearing a file but it is not always there so often not found but done as a just in case.

The fact that it works at boot means it works, you have some non standard permissions issues with the sudo use or with the cron user.

I don't think you need to add more to the script as it handles bringing the necessary network files up and down. Once i get a new sd I will check it on a clean new image in case of recent changes but it seems there is something in your setup.

Can you e-mail me your autohotspot file please so i can test it on my pi.