You are still making this harder than it needs to be. I doubt you will be able to make the ortho ester and do a Michael addition to it. That won't be necessary. I think the connections can be made whether through a direct alkylation or Michael addition. If you reverse the steps, Michael addition is no longer necessary. You can use ethoxide with malonate or acetoacetate.
I hadn't thought through about a reduction needed. However, I think you are correct that doing it from an enol will give the correct oxidation state. If this is made into an alcohol, then you just need to finish with a lactonization.
I would suggest leaving the lactone formation to the end as it may be difficult to maintain it in your intermediate reactions.