Hi Matthew,
Here is my take on your project.
First, for what you paid for it, I'm not convinced that you would be gaining much by doing anything to your kilt.
If you do decide to modify it here is what I would do.
Total cost - about $20.00
You will need 2 yards Hair Canvas @ 24" wide.
A length of broadcloth 2" wide long enough to reach the entire length of the kilt from outer apron strap to underapron strap. A Pillowcase or old sheet will work real well. Any material that has no, zero, none, nada, ziltch, stretch along the grain.
Needle, thimble, scissors. iron, beeswax
A spool of good 100% Polyester thread about the same color as your broadcloth. No one will probably ever see this.
A piece of any thin fabric for a new lining. Inexpensive quilting fabric is fine. You will need three pieces about 24" long by about 8-9" wide. Traditionally the lining is black but this is not a hard and fast, written rule.
How to proceed.
1) cut the existing lining out and discard
2) decide if you want to cut away the pleats inside the kilt. If they are poofy and would cause 'pillow butt' I would cut them away.
3) cut a piece of hair canvas as wide as your Fell is long. Lay it inside the kilt at the Fell. Sew to the inside pleat fabric but not all the way through to the outside.
Every few inches make a 1" fold in the hair canvas. This give vertical stability and adds strength. Use one piece in the center back and one each from the apron edges toward the center back. Overlap the three pieces and sew together firmly.
All the stitching of this interfacing should be very secure. It is what is holding everything together and will be there but hidden for a long time. If this stitching fails the kilt falls apart.
4) Stretch your broadcloth stabilizer all the way across the kilt from the outer apron strap, across the inside, and on top of the interfacing, over to the under apron strap. Sew the stabilizer to the hair canvas at the level of the straps. This is what keeps the straps from pulling and distorting the Tartan or popping the pleat stitching.
5) Sew a new lining on. One piece inside the inner apron. One piece in the center back. One piece inside the outer apron. This covers up all the work you have just done. Make this lining look nice and neat.
Strap on your kilt and enjoy.
Steve Ashton
www.freedomkilts.com
Skype (webcam enabled) thewizardofbc
I wear the kilt because: Swish + Swagger = Swoon.
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