I think you're going to have a very difficult time making a kilt from anything less than four yards, and that will probably be a box pleat, which is perfectly fine. If you want a lot of pleats, you're going to have a hard time getting them with four yards of fabric.

I'd encourage you to look at USA Kilts, as Zardoz suggests. And it's in polyviscose -- washable, comfortable and convenient as all get-out.