My biggest prop is a staff that's about 6, close to 7 feet tall. My brother and I realized that there was a problem when I bought the PVC pipe and it barely fit into the car, so I knew I'd have problems when convention time came around. So I bought some couplers and decided to cut the staff into three sections, and then connected the pieces after I got out of the car. It was also short enough to fit into my suitcase when I had to fly back to Japan, so it all worked out.
But while I'm still living overseas, armor and large shields/weapons have just been out of the question, sadly.
I've got a list of characters ready for when I move back to the States!