I have a belt design that I'm working on because I too feel that the "normal" kilt belt is flawed. As for the heavy kilt I went from a sportkilt (ultralight) to a 8 or 9 yard knife pleat (ultraheavy) to a doublebox pleated kilt (just right). I don't think the weight of the kilt makes it more uncomfortable. I would much rather wear a ultra heavy kilt rather than one that's 4 yards and under 11 oz.