Wow, this was hard to do, I can't lie. This is Michael "Drackson" (as my son calls him). We used DVD videos to sketch the make of the jacket. We bought a 60's style costume and used the little black leather jacket pattern.
Pen or pencil holder made from single mitten. To make face, glue eyes in place about half way down the Styrofoam ball. Poke pipe cleaner in place for nose. Use felt pen to draw a dotted smile.
Take a man's size large crew neck white tee shirt. Take pants and shirt that fit your toddler and lay them out on the shirt. Cutout around the pants and shirt 1 inch larger. Cut out large "spots" from black fabric.
Popeye's arms are two pairs of tights (one inside the other) stuffed in the middle with stuffing and sewn to the sleeve of his shirt. I used some red material to pin around his neck for his collar and his yellow karate belt for his waist.
We cut the stake body out of a photocopier paper box and spray painted it black. For the logs, we cut foam swimming pool noodles down to size and 'strapped' them in with a length of duct tape. We used a pair of suspenders to hold the box onto our son's back.