I recently took out my custom Zpacks cuben poncho tarp and tried it in the more pyramid like style, and was dissatisfied with the amount of room. I and my gear fit in there, but just barely it and it was claustrophobic.
In any case, i'm sort of saving that gear anyways and don't want to put too much wear on it, nor my tipi hot tent set up. So with lack of funds, and no real desire to buy another expensive tent anyway, thought about this.
Materials involved: Thickest polycryo/window insulation film (cross linked polyolefin) i can find, SOL reflective Heetsheets, 2 yards of 1 oz cuben i'm not doing anything with currently (was going to use as a groundsheet or bottom of a bivy) but changed my mind, tyvek tape, Evazote foam, and a water resistant zipper.
I have all the material above except for the thicker, heavier duty polycryo. I'm wondering what is the thickest one can get, what brand is good, etc? I know i need the outdoor stuff, but i can't always find the thickness on the online sites i'm looking at (primarily amazon since i have prime). Some i've seen is only .7 mil thick. Ideally i would like to find at least 1 mil, or even 1.5 mil if they make it??? I'm guessing that 1.5 mil polycryo would weigh about 1 oz per yd?
Concept: Take a piece of thicker polycryo film, some 120 in x 84 in or so, cut and tape heats to similar size (about an inch smaller around the perimeter). On the Polycryo i will tyvek tape a 1 ft square or so of 1oz cuben roughly in the middle (where i will be putting the pole(s) and foam).
A piece on both the outside and inside. On the outside i will tape a small square of evazote foam to the cuben with tyvek tape.
Will do the same with the Heetsheet, except Cuben and foam will only go on the inside.
Guy out areas will be a combo of cuben fiber and tyvek tape (cuben partially covered with tyvek tape and taped on with same).
For the door, i will tape about a 2 to 3 inch wide strip of Cuben partway up the door on both sides (so one on the polycryo side and one of the heat sheet side), taping just the outside. Then on i will slice it down the middle and sew the water resistant zipper on it.
Haven't decided yet if i'm going to go with the one pole or two pole design.
Anyways, in cold weather, the heetsheet side goings in towards me with polycryo outside. Because they will only be taped together at the perimeter, and then held together at the top by the pole(s) pressure, i expect some air space to form in much of the wall area. I don't know yet, but i suspect with the combo of some air space inbetween the films and the reflective, should be noticeably warmer and have less condensation on the inside.
The polycryo will be the primary material taking the load, which will be reinforced with tyvek tape at key points (ridge lines, etc). Also, the cuben will take some of brunt with the pole, as well as the foam where the pole will be placed at. I did this with my Zpacks Cuben poncho tarp and it works great–holds it real well and found out tyvek tape sticks really well to both the foam and to the cuben.
In warm weather and sunny weather, flip it around and have the reflective part on the outside.
I do question the durability some, but i'm thinking with reinforcement of the cuben, tyvek tape, and two layers of plastic film it should last at least a few years and handle some semi strong wind. I primarily want to use it for colder weather, so the reflective stuff will be turned inside most of the time in use, and i will be careful with folding and storing it.
Besides general durability, the other issue i can see with using these materials is some stretching, but i'm hoping if i use the thickest polycryo i can find, or at least 1 mil thick, it should be kept to a minimum, especially with the cuben at the top and the tyvek tape at the perimeter and ridge lines.
Especially looking for feedback on the best and thickest types of polycryo to use.

