I had this issue with my first kilt, and thought it was do to very stiff fabric (100% cotton duck), but now I'm seeing the same problem on my second kilt, thats made of much lighter material (Cotton/Spandex ripstop).

The knife pleats in both kilts lay nice and flat, like I see of all other kilts, when the kilt is laid out flat. However, as soon as I wrap the kilt around, the 'edge' of each pleat pulls away from the 'face' of the pleat under it. When put on, this is a 1"-1.5" gap, all the way around the kilt. I know I'm doing something wrong, just too daft to figure it out.

Both kilts have 2" wide by 2" knife pleats, one traditional uni-directional, the other RevK. Both pleat edges are sewn in, within 1/4" of the edge. The kilts are worn on my hips, with a 42" waist and a 45" rump, with proper allowances sewn into each kilt, 5" fell, with 21" overall length.

No amount of ironing seems to help, the duck kilt has been washed several times, with no change. I know I'm missing something. Please help curb my unruly pleats.