This is the scary thing about obesity. Bariatric patients skew reality. People weighing over 500 pounds are obese; people over 250 pounds are now just overweight. The perfectly healthy "curvy" is now applied to people who are not just curvy, but very overweight, and sometimes in the obese range of overweight.
I am wrong to call him chunky. (Although I do wonder if he's a thin-fat person, with all the fat around internal organs. But this is just noodling, and has nothing to do with anything he's said.)
And I strongly agree about your BMI comment. I should have been a bit more careful - BMI is only useful as a guide that a person may be overweight. (If that person doesn't do any kind of exercise.)