Thanks for all the input.
The main reason I'm interested in this is that I want (my wife wants, and I have to agree I'd like it too) a double wall tent with a top that's all mesh so we can see the stars at night and a waterproof fly for when it rains. We camped for years with a plastic tube tent we used as a ground cloth. If it rained, then we set it up and crawled inside (the tube tent weighed 2 lbs). As we got older, we got a 2 man Eureka tent that weighed 4.5 lbs that filled the bill - mesh top and one door. It was nice to have protection from the bugs, but the tent finally literally wore out. I have a Tarptent Clouburst at 2.5 lbs. It's a great tent, but my wife really wants the mesh top so we can see the stars at night.
I saw a one man Coleman tent at SportMart on sale a few years back for $30 and bought it just because it was cheap. It is a Coleman Peak 1 Cobra. They apparently came out about 1998 and got reasonable to good reviews. It weighs about 3.5 lbs and has an all mesh top with a single hoop pole at the shoulders, doors on both sides (really nice), and a nice rain fly with vestibules on both sides. It's a very cozy fit for two and works extremely well for us. The dimensions are 97" long and 53" at the shoulders/head. It tapers to 24" at the feet and 36" beyond the head and is about 42" high at the hoop. It's very "cozy", but because of the length we have a bit of room above our heads for gear. Our Jacks 'R Better quilt tucks in very nicely along the sides. If I knew how, I'd include a plan and/or pictures. We've used it for the last 5 years, and it's a great tent. The newer versions of the Peak 1 have two hoop poles, the second at the feet, and are up to 4.5 lbs or so.
We've been continually trying to lighten our packs and although 3.5 lbs is really good for a two wall, two man tent with these features, it seems like this one could go lighter. The tent weighs 25 oz; the fly 20 oz, the poles 7.5 oz, and the stakes (8) 3 oz. I figured I could start with the fly and maybe get under 3 lbs.
I've talked to several people now. Narain's in Berkeley has worked with UL materials and gave me a quote for ca. $350 for the fly alone. The materials are about 25% of the quote - Silnylon 1sts are expensive. I've used Narain's before for repairs and they do great work. I also talked to a couple of local seamstresses that I got recommendations for. One said "no" because she felt she couldn't do the quality of work she wanted to for a reasonable price. The other just said she couldn't make any money given the hours involved.
The other tents I've had my eyes on are the Big Sky Evolution 2 D 2P and the Big Agnes SL2. The Big Sky tent looks good, weighs about 2.75 lb and has the all mesh top and two doors. It is about a foot shorter so there's no room for gear at your head. In addition it seems to be manufacured from "unobtainium". The Big Agnes SL2 seems to be about the same but doesn't have two side doors. I don't think my wife is ready for a tarp with a bug net under it yet. I'm also thinking about the SMD Lunar Duo and trying to convince my wife the open sides are almost as good as a mesh top if it only weights 2.5 lbs.
If anyone has seen anything else or has any ideas I'd be very interested. Thanks.