Pee-Wee's Big Adventure Bike

I found this in a "junk box" at a local swap, it almost made me cry, so close yet so far, the mirror is cracked, the stem is bent, it has the amber reflector, and it was a ball of rust, I tried to clean it up but the chrome on these is really thin, and it was pitted already,( but if an N.O.S. one is worth $350.00, this one is worth at least half, right?), or I could use it for a evil clown nightmare rat rod bike.

used 07010 4 inch mirror 002.JPG 001.JPG used 07010 4 inch mirror 003.JPG
 
I found the clown in an ice cream shop that was going out of business - Johnny Shar's Big Dipper in Moundsville, WV. The upper floor of the shop was an amusement park museum. This is the only version of the clown that I have ever seen. I'm pretty sure they re-dressed it and painted the face for the movie. There's one shot in the movie where the original maroon sleeve is visible.
 
He still works! I was a little surprised. Attached is a video link. He really does not sound as bad as in the video. Apparently my camera is sensitive to vinyl-on-vinyl rubbing noises. I haven't quite figured out the mechanism yet. Attached is a pic of part of the mech.

[video]https://youtu.be/boAPu1O_JaQ[/video]

mechanism.jpg
 
The clown has a two-part vacuum formed head. I was thinking of making reproductions of the head since it could be used on any animatronic clown. Due to its age, the plastic has some age and a few cracks. If I packed the parts with modeling clay, would that provide enough support to vacuum form and not destroy the originals?
 
The usual procedure is to fill with plaster and then use the plaster as your new buck. You don't vacuuform over the plastic original because of melting. I doubt clay will work to make a buck.
 
I originally considered using plaster in the original. My biggest concern was the original releasing properly. My mom made plaster crafts for years. Even with lots of mold release, they sometimes just didn't want to come out.
 
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