He's never seen issue in 6", so I'm taking it upon myself to rectify that as best I can.
I opted to use a Sean Connery head as a base, gave him Neill's cheek mole using a small daub of super glue. Here he is all painted up.
Next, giving Grant's signature hat a shot. I'd never tried making one this small before so it was a bit of a challenge.
Cut a tube of hockey tape lined paper towel (naturally) to fit his head.
Trim it down, form the crown, then use an insert piece glued in to cover it.
This was trimmed down a bit further after these photos
Trace out the brim. I wound up using the inside of my hockey tape roll to get a more perfect circle after the initial cutting.
I wound up further dividing the triangular pieces with more cuts, made for more of a rounder fit to the crown.
I added a bit of carnation ribbon as a hat band, and to help cover the glue seam.
Added more ribbon to the crown, paint and floor polish.
A little paint wash, and added a string.
It's a bit rough as a first attempt, but workable for now.
Now to find him a suitable body!