Hey chubby is Sexy !!
Sounds like your going to have quit the exciting Halloween.
For bf I would try making him look tired like he's gone without sleep for several days. Dark around his eyes, messy hair some curl some not. Make him an ID tag something with a crazy name and odd credentials. You can even get those clear ID pocket things that attach to your clothes.
You could always go as his assistant or someone who was his lab experiment that went horribly wrong !!
I have a couple of parties to attend and will be going as a retired play boy bunny. Just imagine a nursing home nightmare and that will be me. Don't Judge !
I don't just dress up I love role playing, I'm going to have a blast . . .