EDM3rd - I stand corrected. I knew "Dragon" didn't sound right, but I never remember the other part. I've driven it twice in a Tahoe and in something like that it isn't even fun.
BILLYANDKRISS your summary is correct. Instead of getting off 74 at Almond, you would continue on 74, thru Nantahala Gorge, to Topton where you would turn right on 129. Topton is at the very top of the climb out of the Gorge - steep but only 2-3 miles long.
Past Robinsville 129 is actually OK until you get to Topoco - it just has the typical ups and downs and a fair amount of curves but I wouldn't hesitate to pull out TT down that road as far as Fontana - actually looking for an excuse to camp there below the dam.
74 from Almond to Topton goes by a stream famous for white water sports, even hosted national competitions. If the weather is descent at all, there will be much congestion thru there on the weekends even in the fall, just take it easy and stay alert and the congested part is only 2-3 miles long.
129 from Robinsville to Santeela is not very well marked in my humble opinion. Seems like there are a lot of secondary roads intersecting at odd angles and sometimes hard to decide where 129 is. Be sure you have good directions and landmarks before you make that last leg, and Robinsville is the last place for a real grocery store and Top Tier gas.
Your return trip is exactly what we do. We live about 20 miles west of Huntsville, AL and camp at Bryson City (really Whittier) twice a year. My return trip is 74 to Cleveland TN, then the interstate to Chattanooga, then get off on US72 at South Pittsburg and go thru Huntsville. 74 is a very good 2 lane road and you can make decent time while enjoying the trip. Between Murphy and Cleveland you will go thru about 15 miles of an area called Ocoee - another Olympic white water creek. There is a 1-2 mile very steep descent as you enter that run from Copper Hill and there are a few tight turns on this run, including one 90 degree blind curve that is famous for truckers to snag each others' mirrors (saw it happen once). It is marked well and they have paved a lot of the shoulder on both sides so you can cheat the curve and be fine. Again, just take your time and enjoy that view as well.
Plan your trip so you are not on the interstates in Chattanooga between 4 and 6PM on weekdays.
There aren't any tunnels on any of these routes, and I don't "remember" any problematic underpasses. We pull our 12.5 foot high TT down 74 many times, but have never pulled it up 129 but that area just isn't congested enough to have overpasses. There is one RR bridge but it must be 100' high between peaks. THERE ARE two tunnels if you pull across Newfound Gap - I would sure check with the Park Service on those two.
Enjoy! Hopefully we will be up there in the fall as well.