Anthony... MAN, you know how to come up with a real good one! But it IS do-able.

You CAN piece the thing together, and the proof is in AmeriKilts and UtiliKilts. If you take a REAL good look at them, you'll see the seams and pieces that make them. I've done this with tartan MANY times... either due to construction, or the fact that the material is "damaged".

Consider that the front apron would be one solid piece. The width that you're talking about is well within the range of the material.

The second piece would be the pleating on the right hip. The third piece would be the back. The fourth would be the left hip. The fifth would be the under apron. This would easily work for a "normal" pleated kilt.

I've had to do this with "emergency" kilts, when the material was pieces. You'll never know the difference when you're done.

Just be sure to use the "mending tape" on the seams, and plenty of zig-zag stitching over the edges. When placed deep in a pleat, it won't affect the hang or sway... and these points can actually hold some of the taper for the hips!