Greetings from Vermont

[biblemonkey]

Off the rack isn't going to be an option. His waist measures 54 and his hips measure 64. Anything I get is going to have to be custom from the get-go.

Also, I think wool would be too hot for him, even in the winter. I'm not sure I will be able to get him to try out wearing a kilt in the winter anyway and wool would smother him any other time. He stays very warm most of the time. I'm looking at more modern kilt designs in heavier cotton fabrics (twill or denim most likely) and in solid colors (green or blue being preferred).

We live in central Vermont, in the Barre/Montpelier area.

Have you thought about polyviscose? I hike in a polyviscose kilt and it very breezy. you also might want to start by contacting the makers that have affiliations with this forum and ask thier advice.