@Alan H, I've had the same thought about lightweight fabrics. I actually bought some supplex a while back when I was talking with someone about kilts and ultralight backpacking. I haven't had a chance to give it a try yet but I think it might make a really great hiking kilt. I wouldn't expect too much kilty pleaty swingy action out of such a light fabric but I bet it'd be supremely comfortable, and that's priority #1.
I've made kilts for two other serious backpackers, and they both opted for camouflage nylon or poly cotton ripstop because it's light-ish and dries quick-ish. One of them weighed his kilt and it clocked in at 39.1oz with pockets, 31.5oz without. I think his hip was mid-50s, so IMO a reasonable weight for the size. I'm a huge fan of cotton and nylon/cotton ripstops for outdoorsy kilts. For extended time in cold and wet weather I'd stay away of course, but for a lot of activities, a lot of the time, in nice-to-not totally awful weather, it's great stuff. I have one headed over the pond for the Three Peaks Challenge in October. We talked at length about fabric and concerns about the weather, and I did put supplex on the table, but he eventually opted for an A-TACS camo pattern in poly/cotton ripstop.
Design-wise, I'm still kind of in the middle on pleat size, about 1.75" to 2", and about 3 inches deep. If I were making a kilt designed specifically for hiking and backpacking then I think your observation about bigger pleats and pleating style would be spot on. I've intentionally stayed away from reverse Kingussie because I don't want to chance running afoul of Utilikilts, but for a lightweight hiking kilt I don't think I'd be terribly worried.
On the subject of chafing down below, I never liked Body Glide and similar products. They work great, but feel a little...icky to me for some reason. I prefer compression shorts instead. Like you discovered, they can be pretty warm in hot weather under pants but there's enough air conditioning in a kilt to make it a non-issue for me.
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