1. My waist (kilt waist) was 60 inches when I started wearing the kilt, and 5 yards of double wide fabric seemed to work fine.

2. I'm about 6' 1" and 54" wide material works for me. Take a tape measure, and measure up from the top of your kneecap. If 54" goes to the top of your head or better, should be fine.

3. Doesn't make a lot of difference. Just make sure the belting is secure, or you will be wearing you kilt at your ankles!