lucky,
If we had to fly out of IAD instead of DCA it wouldn't make that much of a difference so I'm not worried about that. Regarding the layover in SIN, we're already going to have a day layover on the way there (6:30am - 7:35pm) so that's why we wanted to avoid it on the way home. Would there be any other routings from SIN that could possibly go out earlier in the day and go through another city on the way back to DC? I looked but couldn't find anything with C class for 2 seats the whole way home. If we could find a really cool city to stop in, we would even consider possibly leaving a day early and doing a true stopover on the way home.