When making my Knife-Pleated Standard kilts (5-yard kilts), I don't cut out the pleats, but I do put in canvas and steeking. So, really, the process is identical to making a tank except the cutting of the pleats.
How about, rather than reducing the amount of fabric, using a less expensive one?
If you defer tartan and pure wools for a later date, look for a good quality wool mix - possibly with a pattern but not necessarily, you could make yourself a kilt which has all the feel of a quality kilt, the weight, the swing, but on a budget.
If you found a really heavy material you could consider a box pleat, I always think that the heavier the fabric the better the effect with box pleats.
I must confess that having made and worn kilts for a while, I plan for 7 yards or more in each one now, whether it is a named tartan or a poly cotton. I love the variation, and it is not vital - to me - to have a family tartan kilt.
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