David Vaughan, 60, was dressed as Pc Konk, wearing huge floppy shoes, a policeman's helmet and face paint, when he was taken aside at Birmingham International Airport.
He had been booked by Variety Club Midlands to entertain 100 disadvantaged children on a plane as it circled the region on the one-hour charity flight.
But a piece of metal on his costume set off the security alarm, prompting security guards to confiscate his plastic handcuffs and order him to strip down to his shorts and T-shirt.
Staff also demanded he put his bubble mix liquid - used to blow bubbles from a plastic saxophone - into a clear sealed plastic bag.
The clown, from Shard End, Birmingham, said: "The funny part about it was that we were not going anywhere." Mr Vaughan was finally allowed to board the Thomas Cook-sponsored plane, which took off from Birmingham and returned an hour later.
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