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Assuming the kilt is for an average sized man (hips/waist under 46") I never cut out the fabric in a four yard kilt. I rarely cut out the fabric in a five yard kilt. I almost always cut out the fabric in a six yard kilt.
So my rule of thumb is that I expect to cut out the inside of the pleats on anything six yards or greater. But the final decision is really my judgment call after sewing up the pleats. I can feel the bulk of the cloth and just tell if it's going to be too bulky for wear without cutting out the pleats.
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 Originally Posted by M. A. C. Newsome
Assuming the kilt is for an average sized man (hips/waist under 46") I never cut out the fabric in a four yard kilt. I rarely cut out the fabric in a five yard kilt. I almost always cut out the fabric in a six yard kilt.
So my rule of thumb is that I expect to cut out the inside of the pleats on anything six yards or greater. But the final decision is really my judgment call after sewing up the pleats. I can feel the bulk of the cloth and just tell if it's going to be too bulky for wear without cutting out the pleats.
Ditto Matt and Paul. Our 5 yarders are never cut out 7 and 8 yarders are. 6 yarders I rarely get requests for (unless it's a big guy in one of our 5 yarders, in which case I don't cut it out).
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I guess fabric weight would come in to play as well. 12oz fabric might not need cutting where a 16oz may.
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Also, some materials can be hammered flat with enough pressure from the iron, others which are less dense, or contain man made fibres which would be spoilt by the treatment need to be cut out if they are not to impart an inflated look to the fell.(AKA 'pillow butt)
Anne the Pleater :ootd:
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