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So a Brompton then?
Or a Bike Friday maybe.
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http://www.bikesdirect.com/products/mercier/nano.htm
Google Sillgey, Bruno, Gios, there's lots out there with good frames that don't cost that much and aren't too portly as long as you don't require a folder.
I love the minivelo thing going on with the Mayfair folder, but the bike isn't going to survive. Too much seatpost, too much creaking.
Roughly how much is a custom frame, and has anyone heard from theirmatetheamazingframebuilder making a minivelo/folding bike?
Realistically it's not a bike that needs to be light with the best tubes, it needs to survive a taller rider and a harder life.