Here's my attempt, 5.397 tons at launch. I've used a rapier engine, with 8 air intakes and 4 ion engines attached radially. I lauch at dawn to have more time of sun at the edge of the atmosphere. I use the rapier engine till it generates too little thrust and then I extend the panels and turn on the ion engines to circularize. Once in orbit, I make the transfer to the mun in 4-5 burns at the PE. Then, transfer to the mun and retrograde burn to circularize. I aim to land in the middle of the bright side and I reduce part of the speed with the ion engines and close to landing, I reduce the remaining with the rapier engine. As the TWR on the surface is slightly higher to 1 I can finish the landing only with ion. I take off and burn the remaining fuel and oxidizer as I wont need them and enter again in orbit completly with ions. After leaving the mun, a aim to an orbit to aerobreak to get a low orbit. After some tries I find the right place to perform the reenter, I use the small amount of fuel left to correct my trajectory, and, I open the parachute in the right moment to land safely again on KSC. I think this could be improved reducing the amount of fuel and oxidizer and maybe reducing the amount o fion engines. (Moderator edit: HTML isn't supported here. Have an [imgur] tag instead!)