Count my DS in the big melon club. I have to stop my DH from teasing DS too much - I worry about giving him a complex. He was another one who was in the 10% for height and weight and 95% for head. We have had similar problems with clothes getting stuck.
As for Halloween, this year he is going easy on us. Last year he started out wanting to be a minotaur (yikes - how do you make a minotaur) but settled on a Boomerang Warrior, which is a species from Planet Boomerang, Universe Unknown. It is really challenging trying to make a costume to fit an 8 year olds imaginary creature, but it came out great.
This year he wants to be a dark sorcerer - just need to sew a long black cloak with a hood and we are good to go.
It is great to read the Halloween costume threads to see that my DS is not the only one with way out ideas. He has also been a gecko and a phoenix guarding a crystal. He really stretches my sewing abilities, but I enjoy his creativity (except for the minotaur

)