I've actually just finished the kilt. I was able to make the join in such a way that the discrepancy is as small as possible. Good news is that the kilt came out nicely, and I am absolutely glad to have my Heather Isles tartan back in action (My absolute FAVORITE tartan). Only problem is there are a couple of pleats where the bar lines don't "Perfectly" match up due to the selvage inconsistency. I guess its probably not even noticeable, but being the kilt, perfectionist snob I am, I'll always be a little irritated...At least I can't see it, so maybe the feeling will pass...Anyway, pics soon!

Side note--Very strange after having a set kilt size for almost 2 1/2 years. Being a daily wearer, you actually get to know the feel of each kilt, and now that I'm sized up...Its a new strange experience.