Nova Project J5- Johnny Five Aluminum Robot V

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Introduction: Nova Project J5- Johnny Five Aluminum Robot V

About: Entrepreneur, Husband, Father, Shop.com Unfranchise Business Owner. Lovin' Life ! http://www.TimBonderud.com

Thanks to Tom at Joz Robotics for providing me with the Aluminum Alloy Robot V replica. These units are extremely rare to get.

I wanted to take and modify this unit with a working brain and mechanics, and so the process began, rather time consuming because of trying to locate the specialized parts needed for the modification, but well worth it in the end.

Here's a clip from Short Circuit 2. I remember when i first saw this movie, i wanted a mini J5 so bad.


Step 1: Disassemble Johnny Five

Just simply remove all screws and disassemble J5. This part is cool !

Step 2: Track Drive's (Self Contained)

Parts used were

(2) Part # GC0.5-8/60-20 Compound Gears (Gizmoszone.com) These are the Cog Gears Used
(2) Part # GWG0.5-58-31 Worm Gears (Gizmoszone.com) These are the Drive Gears on the moters
(2) Part # GM22 Mini Gear Motor (Solarbotics.com) Drive Moters


Pic 1 - Disassemble Track Drives
Pic 2 - Drill out hole in side plate to fit motor (There is already a housing there it just needs drilled out)
Pic 3 - Take one set of drive cogs and modify one cog
Pic 4 - This is the cog i modified ( The two cogs do look different )
Pic 5 - Cut a portion of the cog off, making room for the drive gear
Pic 6 - Glue drive gear to side of modified cog, centering it the best you can
Pic 7 - Put a flat washer over the drive shaft closest to the motor mount, washer should be against side wall
Pic 8 - Place modified cog on shaft
Pic 9 - Add the other half of cog

Pic 10 - Place some small washers over other 2 shafts, this will help the cogs run true (not sloppy)

Pic 11 - Place the rest of the drive cogs on the shafts then place more small washers as spacers on the top too (You will have to play with the play in the wheel and add spacers accordingly)

Pic 12 - Glue the motor in motor housing that you drilled out then glue gear to shaft., ensuring the gears match up. (This has to be played with until you have proper meshing of the gears)
( Screw the two halves together, if the cogs are to tight you may have to loose a spacer or too)

Pic 13 - The completed independent track drive's ready to be installed on body :)

Pic 14 - Track drives installed on body, ready for testing !








Step 3: Neck Assembly

Parts used were

(2) Nano Turnigy Servo's Part # TS531A (HobbyKing.com)

(2) Piston Shocks Part # 118B-30535 (HobbyKing.com)

Pic 1 - Original neck assembly

Pic 2 - Cut top mounting plate off

Pic 3 - Cut off neck brackets

Pic 4 - Mount Nano servo to the bottom of the top plate. Drill out holes on either side for piston shocks.

Pic 5 - View of top plate with servo installed

Pic 6 - View of bottom of head bracket

Pic 7 - Cut bottom of head bracket off to make it flat

Pic 8 - Glue servo bracket to bottom of head bracket

Pic 9 - Drill out back neck brackets for piston shocks

Pic 10 - Cut of excess aluminum on upper body to make room for servo

Pic 11 - View of rear shock being mounted

Pic 12 - Cut one tab of one side of nano servo (This is for the neck tilt)

Pic 13 - Wire from servo to head bracket

Pic 14 - Mount top plate with servo to piston shocks, and install neck tilt servo with the wire

Testing of the Neck and Head Assembly

Step 4: Modification of the Rear Tire Assembly

Parts - Toy truck from (Walmart)

Pic 1 - Toy truck from Walmart

Pic 2 - Size of tire after being cut down

Pic 3 - Two tires cut down

Pic 4 - Install the 2 modified rubber tires by gluing them on to the original assembly

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    13 Comments

    Hello Bobby

    I bought mine here. Give them a shout. http://jozrobotics.com/

    Has anyone run these through a 3D scanner so they could be printed/milled?

    2 replies

    Hi , these files can now be found in the facebook group for 3D printing. facebook.com/groups/johnny5toy. thanks

    Hi Jonathan. Not as far as I know. Joz robotics was building them awhile back before 3d printing.

    Step 1: Johnny Five "NO DISASSEMBLE!"

    1 reply

    So cool! I never knew they actually made these. I do like the movies and got them both when we saw them available on dvd.

    3 replies

    They sure are cool and fun to modify. The movies are classics :)

    Tim, hi my name is Seth I recently purchased a plastic model of off ebay that you have to paint and assemble yourself, it is the exact same as the ones that joz robotics out out a few years ago. I was just wondering if you ever finished this guy and if you did could you give me details on making the tracks work and having it be remote control because I'd like to do the same. Thank you for your time

    Hi Seth. The instructable shows how i did the tracks and parts used. I have not had time to finish him yet, but it is coming. I will post more as time goes on.

    wow nice , I loved the movie watched it a lot when I was growing up ,
    hope to see it finished ,