I Get the same problem all the time! I know the problem isn't mods since I'm on Console but once patchy came into his human form and I didn't know who he was.
He was bald wearing an orange hoodie from Cool Kitchen Stuff with sweatpants from Get Famous(Which is one of my famous sims' outfits) I recreated what he looked like in CAS but it won't be exact. I don't know if it was meant to happen or if it is a glitch. This doesn't only happen to NPCs it also happens to some of my played sims, sometimes they even end up wearing outfits of their own famous relatives, boyfriends/girlfriends and etc. It was really disappointing to see patchy like that, I had downloaded Seasons a while before that but never got the chance to see Patchy off his tree.
This just happened to me for the first time today. Patchy showed up inside the house a few days ago for the first time (scared the crap outta me) - but today he showed up in one of my famous Sims outfits.
I think, in my case, it's the "Trailblazer" perk - one below the "Lifestyle Brand" perk for famous Sims.
It *is* funny - but some "occupations" (like Grim and the Scarecrow) should not be subject to the whims of current fashion!
I also had issues with patchy appearing (and yup- bald). He also had no name listed in the relationship panel, and when he passed from old age he was listed as "____ has died" (I knew it was patchy because of his appearance). This happened after I had deleted patchy from my sims lot (so that I could keep the lot after disabling seasons). I didn't expect Patchy to remain in relationship panel after having deleting him from the lot.
