If you want to your own Sparlock, here is a link I found:

CaptainSchmideo

http://www.ehow.com/how_7460300_make-plastic-toys.html
cyberjesus

SOunds like a good project
darthfader

Intersting concept... I'll look into this -- maybe fabricate the first Sparlock from ploymer clay as the prototype and then use silicon molding compound for the "mass production"... thanks!
Berengaria

LOL, when they come to your door, hand them Sparlock. Appear to be taking direction from Sparlock during the conversation.
Black Sheep

http://www.headbobble.com/gallery.html can probably do a head if you can supply front and side images. They also do custom bodies, so they might have what it takes to do the whole job.