So funny you posted this - I had a woodpecker request for Halloween as well! Can't wait to hear people's ideas.
I would paper mache the head/mask/beak...using cardboard for the beak itself. If you blow up a balloon to roughly the size of your child's head, you can build it up a layer at a time until it is just what you are looking for...oh, and I would use cardboard (from a cereal or cracker box) for the beak as the bottom layer of the paper mache mask. Regardless of how you do it, I hope you will share pictures.
I would say a little red peaked cap with the black clothing, and then face pencils? Can't wait to see what you come up with!
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