Lance
On the single skin issue, my own take is that it’s going to be much harder to pull off than the tarp and inner approach. As you’re finding, getting the geometry right, working out how to assemble it, and ensuring that the netting will hang right in sub-optimal pitches is quite challenging. With a tarp + groundsheet/inner design those problems go away. If you use the well reviewed RSBTR 0.5 oz Noseeum mesh any weight difference should be minimal. Yama have a tutorial which would give you a good starting point for sewing an inner or bivy:Â https://www.yamamountaingear.com/diy/net-tent/.
I don’t know how experienced you are, so forgive me if this is stuff you’ve already considered. But many people prefer the tarp/inner for its flexibility. In summer with no bugs you can just use an ultra-light ground sheet. In winter you can use a solid inner. When it’s wet, you can pack your inner separately and protect it from the sodden outer. If you want the option of cowboy camping, you can set up the inner on its own to keep off bugs and critters and shelter you from the breeze. When it’s ghastly outside, you can push back the inner and create a large safe space for cooking under the tarp. If you design the tarp right, in bad weather you can pitch it lower to shed the wind. Yama have a smart design that allows you to do that with their Cirriform single skin, but it would be non-trivial to implement, I think. Lots of advantages to the tarp approach – I personally much prefer it.
On the bonding, someone posted about a MYOG tent where they did this, and they said it lasted well. But I can’t find the thread – I’ll post again if I do.
I’m far from a expert on bonding, but my guess would be that you’d sew a strip of whatever you’re using for the fly to the edge of the net, to give it some additional strength. Then you’d clean both surfaces with care and roughen them a little, spread the hem of the inner with a thin layer of silicon sealant (or Seam Grip if you’re using silpoly), press the seam carefully against the outer, put some weight along the join and leave it to cure for a day or two. There’s quite a lot of info on bonding if you search the forums. Personally I’d set up some test pieces and leave them outside under some stress for a few weeks to see how they stood up.
Anyway, hope there’s something here that’s helpful.