DanAyo, sounds like you have a fun project ahead of you!
I agree with Kit; the 1.6 shell will make for a more durable quilt in the long run, but I think it would be over kill as a liner. I assume the HyperD1.0 has a similar feel, so you could go with that as your liner. Personally, I use Argon67 Taffeta for my liners and it is very comfortable.
I use a zipped footbox on my CS Apex quilt, and it has never bothered me in the least. This is also what some vendors use (EE, etc.). A flap of your HyperD sewn into the seam of your quilt is option if you think it will be an issue.
For the foot cinch I suggest sewing a channel, probably of your shell fabric, onto the shell itself. Do this before sandwhiching and sewing the insulation/liner/shell together. I put my channel about 2" off the edge of the quilt. I put one cordlock on either side of the channel. With this set up, when you cinch up the foot box, there is that little extra bit of insulation on the end that gets scrunched up inside the quilt. This helps seal it up tighter than just channel on the end of quilt.
I took the same approach on the head end, except I put a grommet/button hole in the middle of the channel for the cord lock to adjust. I also put a 3/4" grosgrain tab on each side of the head end of the quilt, with a plastic snap to connect the tabs. This lets me snap the sides together behind my neck, then adjust the cordlock right in front of my face. this pulls the quilt nicely around my neck. Again, that insulation that is outside of the channel acts as a bit of of a baffel to seal out drafts better. Not as effective as a nice big overstuffed down collar would, but better than a simple channel in my estimation. On my first quilt, I left the ends of the neck channel open, and then tied off the ends to the grosgran tabs. This makes it easy to swap out the cord if I ever wanted too. On subsequent quilts, I have sewed in the cord. Both work fine.
Foot box channel (foot end of the quilt ends about 2" to the right of the channel):
IMAG1835.jpg
Neck Channel with gromet (head end of the quilt ends about 2" to the right of the channel):
IMAG1836.jpg
Hopefully this helps!
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