I just bought a Midway Shooting Gallery Deluxe that is in great shape last week, but was totally missing the rubber clown. The metal bracket was their, but no clown. Once I got the key and got inside the machine, in the back I found what must have been an original replacement clown that was left inside!! It's used, but fully intact and in great shape except for a dented nose. The rubber is too rotten to even think about using it as it would not last long, but since its totally intact and all the colors are still there, I'm going to make copies of it. 3D printing might be an OK way to go, but unless one prints with various colors for each color layer, I can't see that doing something like hand painting the output print would hold up that well to being shot at all the time with it being hard plastic.
I'm making a mold and will be making copies of the clown using a flexible colored rubber resin casting material. Each color on the clown will be colored layer of rubber, so it wont wear off or chip (least that's the idea). I just have to get the right hardness of the material so its strong enough not to tear off its metal bracket, but also not so hard that its like solid plastic and still will still have some give to it like the original would have.
My discs are intact, and the globes are fine, but the blue side clear disk has a couple of cracks in it that I'll just be filling with a clear bartop style epoxy, but I might try and make a full mold of those as well and see how it holds up to being shot at with a couple of different casting epoxy. If one had a vacuum former, those would be easy to make out of a clear poly carb sheet, acrylic or similar that's strong enough to take the hits, but I don't have access to one (but I might try make a vacuum mold just for the fun of it).
If the clown turns out well and holds up, I'll let you all know as once the mold and material mix is figured out, its just as easy to make 10 as it is one.
The one thing I would appreciate some help on, is the motor for my clowns movement is totally gone. It must have malfunctioned at one point and was removed so my clown is just static at the moment. The bracket, wiring and the pull rope and pulley are in the machine, but no motor. Is the motor assembly the same or similar as the one that controls the disc rotation? If someone could post some pictures of it and its connection to the clown, that would be a big help as I might be able to jury rig a new motor setup in some way.