Hey all. 1st post here on Pinside but I've been lurking since buying my 1st pin just over a month ago; a Road Show. First off thanks to all, there is a ton of awesome information on here.
Reading older posts, it seems people are constantly having issues with the plastic gears that drive Red, Ted, & Rudy's jaw either breaking or binding. I've had both these issues since owning the game, and the replacements I've gotten from various suppliers have had the same issues. I decided to make my own out of metal. So far I've only made the 14T & 56T gear (03-8471) and it was pretty simple. That said, I did this for a Road Show, not 100% sure it'll work on Funhouse.
I just took two gears meant for RC Cars and joined them together. The 56T gear has a pitch of MOD 0.80. This gives it the proper diameter and meshes with the motor. The small gear has a pitch of MOD 1.0 and I used actually a 15T gear (vs. 14). It meshes nicely with the sector gear. I got them on Amazon (unfortunately in sets with others I don't need):
I drilled out each gear to a bore of 3/8" (on a press) and used JB Weld to epoxy them together and onto a sleeve with an ID of 1/4", perfect for the bracket they ride on. I used a bolt with masking tape to align and clamp them while the epoxy set.
So far I have the dual gear installed, and it has peen playing well so far. Time will tell I guess. Still waiting on some other parts to reproduce the sector gear. Will update when I do.