Well, this isn't finished yet. Still waiting for a replacement gunbelt/holster (thanks Paul!), and I need to glue the shirt to the body in a few places, and the jacket to the shirt (to help with the sense of scale), and it needs dusting up a bit... but largely it's done. Here's what I've done so far.
First the shoes were repainted and weathered to look old and dusty, the trousers the same.
The top fastner on the shirt was removed, and it was cut, folded and glued so that it would be able to be posed with the shirt more open if I wanted.
Some fabric was cut out of an inside seam, and this was glued on the inside to proved cover and added strength where the original 'cut' was on the shirt. After that it was soaked in water that was coloured with black/brown paint to give a more correct colour. Then more watered down paint was painted on to age the fabric, then give sweat stains.
I wanted it subtle though. Invisible weathering is what I was after.
Then the head/neck was sculpted into one solid piece (as seen previously).
I took the jacket (which often looked too big/not creased and folded enough) and cut open the inside seams.
Then I glued a thin ribbon to the inside by the zipper, and made some 'belt loops' on the inside, and threaded the ribbon through these. Then when I pulled on the ribbon, the jacket pulled in like a concertina, creating folds and crumples. Also it made the jacket appear thinner. Once I had it right, I glued the end of the ribbon to the inside, holding this shape permanently.
I realised that his trousers sit low when they look the best, and he has a flat arse... so i created lower, bigger bum cheeks out of cotton wool and glued them on.
The waist/stomach looked to thin, so I took some kitchen roll, glued some cotton wool to it, and then glued this to the body, providing the correct shape I was after.
continued in part 2.....