I have a new toy that's perfect for your needs. A 3-D printer.
You can get a decent one for 200 bucks (often on sale for half that I think Micro Center is pushing 'em at $99 off just now)
And you carefully draw the flapper or scan it (Another toy I don't have)
And print it using one of the higher temp tougher plastics.
I'm printing with PLA (Good to around 120 F then it gets soft) but it's way stronger than I expected it to be.
And you can make signs. and toys, and parts (I have a collection of plastic parts for selected RV devices) Cost to print a part is about 2-3 cents per Gram and stuff takes very few grams as it turns out.