Quote Originally Posted by M. A. C. Newsome View Post
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).