My "Jedi" kilt (See Greenville game pics) has a total pivot-to-pivot sett of about 4.5 inches. I did a 1.5 sett- 6 3/4 inches per pleat. For box pleats the outside face of the pleat is 1/3 of the total pleat with an ideal range of 2-3 inches (confirmed with Matt). Thus the 1.5 sett would give a 6 3/4 pleat with a 2 1/4 inch facing. This would look good, feel good, and be rather practical.
Now, I'm thinking of this material (dang it!) of myself.
A box pleat would work quite well and not be a HUGE amount of work. Now, back to working on my current project-> a box-pleat in "Green Stewart" sans the blue stripes-> I go it cheap, its wool, its practice, and the colors match my car (a Miata painted in Lotus Racing Green, Lotus Racing Yellow stripe, and red leather seats and door covers over black carpet (based on the Team Lotus racing cars).
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