Cutter,
Thank you for another good video Skype call yesterday.
I agree that for what you and your customer intend to do just moving the straps over to get your customer in his kilt for this weekend and then, later, trying to resolve the problem correctly is a good viable solution.

And just to put you mind at ease. No Barb and I are not going to start a fight. To fully understand this forum you have to understand that Barb and I are friends. All of us her on this forum are. We respect each other even when we disagree.
Barb and I come from different worlds of kiltmaking. We each have our own ways of doing things based on our experiences. You are being offered different ways of achieving what you need to satisfy your customer but it will be you, who actually has the Kilt in front of you, who decides how you will proceed.
If you choose to take Barb's advice that is good. I will not be upset in any way. I just want you to have the option of another persons way of doing a job.
And Barb and I will continue to disagree on some things. That is the beauty of this forum.
I know of no other forum where you can be offered the advice free, without flaming, or yelling. Where the only thing that matters is helping another professional to achieve the best look and fit to the final product.

And after seeing your workshop I am confidant that the final product will be wonderful. Just seeing your tools tells me that you know your way around a piece of fabric. Looking over your website tells me you are a true craftsman.

I thank you for giving me the opportunity to help in whatever way I can. Please say hello to your wife for me and I hope you will continue to keep us posted on the results of this unfortunate experience.