I can't remember the exact procedure for making them but I think you right click on the emotes icon and browse, then there's a button there for making your own.
They always come out as 15x15 size.I mean the big ones.
www.emoticonize.com
I see one of Packer's avatars there. :D
I'm thinking I should report it but I'm not sure.
But he's tonce D: