Head Building

Johnny 5 – head build.

This page is about building Johnny 5’s head, check out the main project index for the rest

This page has details of the head build based on CAD files which I got from this facebook group’s file section.

There’s a YouTube video about this

I’m building my Johny 5 at half scale. This is because a full sized Johnny 5 is gigantic, it won’t fit though normal domestic doorways, and weighs quite a lot. A half scale model is half the height, but also half the width and depth, so it’s actually eight times less volume, so my power to weight ratio for driving it along will be much better.

I’m basing the head on CAD files which were created Terry Andrews of Input-Inc, and have been uploaded to this facebook group’s file section. However these files were not officially released by Input-Inc because they were essentially failed prototypes which were then shared by someone else. I’ve made quite a few modifications to the original files so they will print, and also bulked up certain aspects of them so that, at half scale, they aren’t too thin.

There are however some areas which have printed so thinly that there’s hardly any plastic there – these are largely places where additional panels/features cover the detail however. I imported the STEP files into Autodesk123D for modification, which is free software. All parts were printed on a Lulzbot-AO101 with a 0.5mm nozzle and 0.3mm layer height, in ABS plastic:

Assembling the parts – I’m using ABS dissolved in Acetone to stick the parts together:

I’ve left the top of the head lose so I can access the inside:

As I have printed the parts in ABS I can use Acetone to smooth the pieces. This is a similar process to the lid of my Mr Fusion prop.

More to follow…