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There is a closed FaceBook page (if you do FaceBook) called I Want To Customize My Johnny 5 Toy Robot! that is one of the most amazing sources of information about Johnny 5.
Their gallery includes an extensive photo shoot of one of the actual Johnny 5 robots fully dis-assembled (NO DIS-ASSEMBLE STEPHANIE) with rulers for accurate measurements.
There are also CAD files of the Original Johnny 5, the toy robots from Short Circuit 2 and a ROBOT V toy that was produced in Hong Kong that resembles Johnny 5.
Many people in this group customize and build various Johnny 5 models and are often happy to share. But there have been a few bad apples who have come into this group, asked for and got lots of help, only to then try to extort and profit from the help they've received. So there can be a little distrust when someone comes in looking for help straight away.
But if you explain your plans, and look around I'm sure you can find loads of good genuine source material to help you get started.
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