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Theres a few characters with returning roles that show up in the show as sort of gags. This one your talking about is Minamoto-san (a carpenter) who was used as a reason in an SBS why the door Higuma had kicked in was mysteriously fixed in the following scene. Since that SBS occured, his character has been seen randomly through the anime, and his role is that of comeone who is compelled to fix doors
the most famous though is Pandaman who has appeared in both the anime and manga multiple times (you can find him on the Kuro Neko pirate ship (Captain Kuro), on the Baratie in the midst of the mayhem of Don Krieg's attack, In Loguetown right after Buggy is struck by lightning, and in the bar where Smoker and Ace meet.
There is also Sam-sam, who is a drunk always coming from his daughter's wedding and seeing a party while already drunk, just joins in (as such, look for him in most celebratory scenes (such as in Cocoyashi village).
Also to be noted is the brand name Doskoi Panda which is a parody of the Acme products of Looney Tunes fame. There is also a nock off version of the product at low quality called Dosko1 (think of seeing a sidewalk merchant seling Prodo bags. kinda looks like Prada, but for 1/5th the cost, and consequently the quality). There is also mention of Cyberpanda as another brand that while being an imitation of DP, actually sells for more than the original brand. I have not seen this brand appear in the series of yet though sadly.
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