I hate that all these small bit characters are up against such titans. The Captain's great, but Grandpa is greater.
Threading these is always tough because you don't want the one and two to go against each other in the first round but if you do a 1-64 power ranking you end up with a ton of blowouts. I used a chart for how many lines each Simpson character had and threaded them that way.
I feel your pain. I used to run a tournament on another forum and seeding was always contentious. I felt there was no good or easy way to do it, so I ended up just randomly generating the seed. We'd almost always get at least one competition early on that could've been the final. It had the benefit of keeping the contest interesting throughout, but it also meant we might end the tournament with a dud of a final round. It's a tough thing.