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A few years back, I came up with a really elaborate Inspector Gadget back story.
See, when they put out the Dr. Claw toy (like 2-3 years after gadget was off the air), they showed his face. He looked just like Gadget but older. That's where it all started.

I decided that Dr. Claw was Gadget's older brother, and as evidenced by his metal arm, had gone through some kind of mechanization process as well.

Gadget was the first test subject, and the process was so painful that it fractured his psyche. He reverted to an asinine goofball personality. Because he was deemed worthless by the agency that created him (presumably the same agency that "Chief" worked for), he had his memory wiped, and was retired from the force. Shortly after, his elder brother was put through the same process. Instead of becoming a simpleton, he became an evil reflection of who he had been. He slowly build up his criminal empire, and at last made his deceit known in an attempt to destroy the agency. Fortunately, his daughter Penny had seen the changes occurring, and, with the help of a computer book stolen from her father, and a dog his experiments had created, she managed to stop him.

Appearances deceived though, and it appeared that Gadget was responsible for the victory. The agency concluded that while in his private life he had become a dullard, he had somehow remained a competent agent. He was returned to the field, and given charge of his brother (now Dr. Claw)'s daughter. For the first few seasons, he had difficulty activating to correct "gadget" due to the mind wipe, but time and again, Penny and Brain came through for him, and the world.