This is a great forum, I'm glad I finally "de-lurked" to ask this question. I will pass this information on to the scout's family. It sounds like he should at least give the XXL a try. M2M for only 20% more would probably be an acceptable deal... but having to order two would not.
Our pack doesn't require the cubs to wear the pants (I know, I know! But they outgrow them so fast....) so only the shirt and perhaps the hat are an issue.