The guy with the basting thread still in place also has a kilt that is WAY too long. Or is it that it was made to be worn higher (traditionally) and he's just wearing it on his pants waist ?

My wool kilts were both ordered to be worn on the pants waist - low. Both shops agreed that it was OK, and they were well versed in making them this way. Yet in both cases, the fell is still 4 - 6", which of course, is the problem. That causes the pleats to open far below the point where your butt starts and you need the extra room. So that makes it tight and not as comfy or easy to move around in as it should be. And because the length is short, wearing it higher is not an option either.

Is there a construction reason the fell can't be around 1 1/2 to 2" ?