my question is (I know this is a fuzzy area) about how much time needs to go by before someone (me for instance) would be looked upon as a non JW worldly person?
It is in fact a fuzzy area. As others mentioned it really depends on many factors. In my case I moved to a congregation where no one knew me and then faded. I also moved a lot. Then there's my "F-U" attitude towards them, so in my case they were actually very eager to pretend that they don't even recognize my face.
I have family that's in (they all live at a distance), they tend to be by the book so I'm just trying not to give them an "official" reason to shun me if possible,
Sorry to hear about the things you have to go through to manage having a relationship with loved ones. Question: are you comfortable with half truths and lies? The easiest way is lying to them or mislead them to believe something (to that they are very well conditioned by the WT). If not, just try to keep things general and vague. That way they may have some sense to leave you some space. I don't think that there are easy answers.