Chusai and Sogolon
You can't make "tattered" clothes, and you can't change a person's weight or height (though you can achieve a "weighty" effect by loading on the armor). I gave Arnak a fur vest and kept everything else in green tunic and brown leather, and of course the black boots. None of the given swords looked like what you described, and all the axes are gigantic; I thought you said something about throwing knives, so I gave him a set of Kunai. Just before Arnak slams down Ganondorf in a great piledriver move. Yeeha!
I had a lot of trouble with him. There was nothing even close to what you described as his uniform in the game, so I tried this.