I would have to disagree on the Army blanket weight, its really more like modern 18oz cloth. Earlier this year I made a joined plaid from a special run of slightly wider than single width cloth that Issac Walters had made. I used a normal back stitch to join the pieces. I also following the information in Peter's paper on the Geo IV'th joined plaid put in a drawstring. Im quite happy with it. The draw string loops were made with some of the Inch wide wool twill tape that Wydean makes, and in the same green like what you see some MOD Kilts finished off on the top.

A great kilt is never going to look like a modern kilt, and the pleats will most likely be covered by the back draping of the plaid, so they are not the design element that they have become in the modern garment.