Quote Originally Posted by Cutter View Post
(It's like rocket-science to me, you know. Seems different laws of physics are at work. For instance, had no idea how a garment so heavy can stay on a heavy belly. Turns out, kilt-wearers don't breathe much?)
Here's a kilt concept that helped me understand their construction (talking about the traditional knife-pleated woolen kilt you're dealing with here, not modern demins and the like). The buckles are attached to the inner canvas/stiffener, so the wearer is "wearing" the lining and inner construction. The woolen outer garment is attached to the lining etc., but is more free to float and swing as the wearer moves.

Here on the forum, "tank" is commonly used to describe these traditional kilts. It was originally coined to indicate their durability, as in "made like a tank." However, I also think of the wearers as riding around inside the garment, like the soldier inside a tank. Not sure this image will help your project but it did help me visualize the construction.

Vis-a-vis reworking pleats and aprons, take note of the A-shape of aprons and the tapering width of pleats that should exist in the original garment. This change in circumference from hip to waist is a main factor in keeping the kilt in position on the wearer, and must be maintained (or improved) as you alter the garment to this wearer.

Hope this makes sense! As Canuck noted, you might be able to get him through the event with some buckle trickery, if the full re-work couldn't be done in time. Best of luck.