While there may be much debate about how, when, and where kilts were worn, they are comfortable and popular so this is a resource page for making and wearing yours. I am not worrying about historical accuracy here, this page is for those who just want something fun to wear.
A kilt is a rectangular piece of fabric that is 60-80 inches wide and 3-6 yards long. They were traditionally made from Wool. I have seen rumors they were made from Linen. Flannel is cheaper than wool and comfy in the winter. Cotton is comfy in the summer and can be as little as $1-2 per yard (45 inch wide).
Go to your favorite cloth store (Walmart, JoAnn Fabric, Hancock...) and pick out a plaid you like. Make sure it is 100% natural fibers (wool, linen, cotton, tensel) (no polyester, no rayon). Plastic cloth doesnt breathe well. If the fabric is less than 60-80 inches wide, buy twice as much as you need. Finding $2/yard 45 inch wide 100% cotton plaid at Walmart, I bought 8 yards for a 4 yard kilt.
If your fabric isn't wide enough, cut it in half. Now I would have 2 panels, each 4 yards long. Sew them together long side to long side. Now I would have 1 big panel 4 yards long and 45+45 inches wide.
Hem (or fray if you know how) the short end (the 45+45 side). The 4 yard long part should be the selvage (not loose threads) and only needs to be hemmed if funny things are written on it.
You may notice that many people wear shirts with a kilt. You don't have to if you don't want to. To make a shirt, take the following measurements:
All of the directions on these resourse pages accomplish approximately the same kilt fold. Pick which ever one makes the most sense to you.
Scroll down for easy wearing directions as well as several different options for wearing the top part.
Quick Kilt instructions
Pictures of Man putting on Kilt from Garb the World