I know this is an old thread but I took the pvc idea and began to work on our own Guys. The only previous experience I have with noodle types has been Stringbean from Out of The Box Puppets.  I bought that pattern and made 5.  Some of the expert things Julie taught me with that has helped but I am totally Lo-Tech!!
I am taking notes and pictures along the way but was not sure if I could post them since I am using the Playsoup Hubie Tubies as a reference. I am using 1/2" webbing through 1/2" pvc for the shoulder and hip joints.  Just not really sure on the length size of all the tubes.  It will be smaller than Playsoups I think, since I am using 3" hollow noodles and a little shorter since I am going by my own height.  I am now trying to figure out the mouth size for the head.  A 3" tube does not give enough room.  I think I will have to extend it back and hide with black.