Bren... as stated in my PM and email:

The IS some natural "expansion" that humans go through on a daily basis. Keep in mind, you got the Casual kilt, and the velcro is very forgiving (vs. our Semi Trad which has straps and buckles). Put your mind at ease about the measurements being too big or too small. If they are, you just match the velcro up at the 'right' spot and put a belt on and away you go. It's not nearly as "exacting" as you're worried about on the Casual. That's WHY we use velcro... there's a bit of a 'fudge factor'. It'll fit fine, I promise.