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So we've made a little more progress and I am just not happy with the results at all.
I was right in thinking that the yarn is too bulky, the needles are too big and the chart still isn't quite right. I want to keep going with this sample so I can flesh out other difficulties or refinements. The nose needs to be reduced by two rows from five to three, and I've not finished the eyes yet, but they need to be changed as well, perhaps a stitch or two wider.
Trying to intarsia the whole thing is a mistake, I think that the nose and eyes should be duplicate stitched after the motif is complete.
Sigh...

Well some progress has been made. I don't want to copy the scarf exactly, that wouldn't be ethical, but I am finding that the chart I did isn't quite up to snuff. There are several things at this point that definitely need improvement or change. The crossbones need to more diagonal, and I need to figure out why my stitches are doing that weird thing at the bottom.
Looking at the chart, the picture and the small knitted sample above, mine is much smaller, the crossbones are wrong, but that's OK, I can fix it later. One is taken by the iCamera the other is scanned, the scanned one is vertical.
I haven't posted the chart, because I don't want to give the impression that it is in anyway done or the final product. I really wanted to document the process and progress as I knit and refine the pattern idea.
So far not so good.
SAMPLE: Knit with Bernat Softee Chunky 100% Acrylic in Black and White on size 10-1/2 (US) needles.
Notes for improvement based on current sample.
Changes:
Yarn to worsted weight (perhaps sport?)
Refine / define Crossbones.
Change Needle size, to 8 or 7 (US)
What is up with the stitches at the center bottom?