I've been a real slacker about adding the content to this page,
http://www.tkbearcrew.com/costume2.php?costumesid=27
but I made my own helmet, shield, and spear from scratch. Although, I am a little hesitant to post more of my pics, becuase last time I posted some of my spartan gear, somebody told me I was too fat to be a Spartan...I'm 6 foot and 155 pounds..... :unsure
You can see some of the progress shots here:
http://www.tkbearcrew.com/gallery.php?level=album&id=51
Helmet was cardboard base. Shield was a 36 in saucer sled that had the interior fiberglassed for for rigidity, and the lambda built up with styrene, and the whole exterior given a coat of Bondo. Spear was pvc pipe with wood grain hand painted on. Spear point was carved out of bondo.