I like your reasoning Sciuropterus (and your nickname, takes me back to my mammology days). You are quite right, just buying fabric at retail prices is rather expensive. A quick pricing of tartan at the Kilt Store shows that it will set you back about USD 300 for 4 yds DW.

For me, its not about economics. I am utterly and completely fascinated by kilts, and the best way for me to learn as much as I can (at this point in my life) is to construct one. I also have an inexpensive Stillwater that needs major alterations, and for its price, it is not worth paying someone else to do it.

It's how I am with about most everthing I do, computers, bicycles, cooking, brewing, etc. I like to get my hands into it, and learn along the way. I am a research scientist in molecular microbiology, so I guess it is in my nature to tinker....