Try posting this question on the Wheelman forum:
http://www.thewheelmen.org/
I know there's a company in WA state that does repro badges, and it's not a big deal when they have a sample to make a mold off. But I'm sure there's Wheelmen folks (Dave Toppin et al) that can steer in the right direction of making your own as well.
Sounds like a cool project. Good luck, Otis
Jon Williams Grants Pass OR USA
Wish I could find an unattached Pierce "Racer" badge to have copied!