You know what kids, I think I've got it all wrong.
Normal is easy and anyone should be achieving that.
Hard without breaking anything is actually pretty tasty.
Extreme, I don't think is actually legally do-able without ions.
I've spent most of the night attempting the most cheesy efficient, no holds barred maximum Dv capable but realistic SSTO design.
And I'm short a return trip by quite a margin.
Most of the SSTOs in the post I referenced claim a return for under 4,000m/s. Johns generates just short of 4600m/s.
The one I've built produces between 4844 and 4906m/s (this is with a probe, landing gear, parachutes and aero surfaces at 6.35t total), and I'm out of fuel 2/3rds of the way back into lunar orbit after landing.
I even got into the weeds of where I'm spending it (numbers taken from whole fuel percentages and may be slightly off actual).
LEO 3334.95 m/s
TLI 703.50 m/s
Landing 551.43m/s
Total = 4589.88m/s
That leaves me with 255.06m/s to lift from the moon and encounter Earth for some aerobrake and parachute action.
The problem is several fold.
The biggest budget burner is the lift to LEO. Cos of drag and a low ish TWR, the Dv score is about 4-500m/s higher than the 'industry standard' (which needs revising in my opinion). I could
maybe get the launch down to 3200m/s as that's the lowest I've seen properly work.
TLI is almost bang on the map prediction and considering I'm going off whole percentages, I'm willing to take that as a graphical inaccuracy.
The landing isn't from LLO. That's from the direct injection, suicide burning in from 30km Earth apoapsis to 2000m lunar periapse like a madman. I could probably knock 50-100m/s off that. Which is about 1/2 of a percent of the fuel onboard.
.
Next comes the TWR and Dv problem. 4900m/s is on the limits of what an SSTO in game can generate and cos Tsiolkovsky is a harsh tyrant, adding more fuel isn't saving me as I'm well into the realm of diminishing returns.
For example, 4,000m/s can be achieved with 3 engines and less than 100t of rocket.
4850m/s needs 17 engines and 660t of rocket.
4950t (depending on engine combo) can be 1200-1700tons.
The theoretical maximum with infinite fuel mass is 6347m/s, with just engine and fuel.
You can see where I'm going here.
And then comes TWR. 4850m/s at 660t requires using the best stage engine in game, Broadsword.
Lots and lots of broadswords.
But the engine base TWR isn't amazing, and there comes again a point where adding more engines to increase TWR just instead adds fuel mass to power the new engines without actually increasing relative TWR.
Worse is the more engines you add beyond a certain point, the TWR actually drops as the fuel required to feed it outweighs its additional thrust. This is especially the case when you bump in a hawk or titan for a bit of that extra base TWR they have, but the low efficiency means extra fuel which nullifies the TWR increase.