Thanks for the great feedback everyone! So here's an update:
1) I decided to make my own UQ with some ripstop nylon (which seems to be the overall consensus here)--which grade, color, etc is still TBT. There is a great industrial fabric warehouse near me that's open to the public once a week. I'll check there first, but if I can't find anything for a decent price, I'll check out GearSupply. The down, as I mentioned earlier, I already have in spades (probably enough for a UQ, a TQ/sleeping bag, and plenty to spare), but it is of questionable quality.
2) I'm already practicing my sewing and baffling skills! The fam and I are going on a car camping trip near the BWCA in a couple of weeks, so I'm 'retrofitting' the sleeping bag my son has now outgrown for my daughter. This new design should be substantially smaller, lighter, and warmer than the original. All good things. I removed the batting and tapered the bottom half (like a 'partial mummy' style). I also added 3.5" high baffles to just the front (slightly more than) half of the bag, converting the back shell into a pad sleeve; the down would only compress in the back anyway and won't do much to keep her warm. After stuffing the baffles today, it has a generous 3" of loft in the front. We have travel cots for everyone to sleep on--perfect for car camping as they are quite compact, but not really a suitable for backpacking trips (3-4 lbs each). Anyway, these cots do get drafty and cold underneath due to the 8-inch gap between them and the floor.
This raises another question: my kids haven't been backpacking yet and don't own pads of their own. Do you think a pad--fit into the bag-sleeve--made of reflectix will be enough to keep her warm on the cot (keeping in mind the high-loft top quilt of the bag)? If not, any suggestions for a cheap kid's pad?
So after learning a few things from this first project (e.g. the importance being in an enclosed space and covering clothes/face before baffle stuffing), I think I'm ready to invest in some nylon and tackle my UQ project. If I can finish it before the BWCA trip, I may forego the cot for a night or two to test it out! Thanks again everyone. Y'all are awesome.
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