"My Relentless Saga"
How I Finally Acquired an Authentic "B9 Robot"—And How PROPOLOGY Became a Subcontractor For Its Manufacturer: B9Creations
By Richard Molnar
My Wonderful (and Arduous) Journey
In the late 1990s, I set out to build a highly accurate replica of the Robot featured in the iconic 1960s television series Lost in Space. This unforgettable character—known simply as “Robot,” (AKA: “Robot Model B-9”)—was brought to life through a brilliantly imaginative prop design. Ever since I first saw it on screen, I’d dreamed of owning one. That fascination undoubtedly played a key role in sparking my lifelong passion for crafting custom props.
Preparing to Build
To begin, I immersed myself in researching the original prop, compiling an extensive library of photo references to guide my replica. During that process. I came upon a vibrant online community of fellow enthusiasts—people from around the globe who were just as captivated by the Model B-9 as I was.
Me and my fine B9
It turns out, building your own Lost in Space Robot has become something of a shared passion among baby boomers—a nostalgic pursuit blending childhood wonder with grown-up craftsmanship.
Contact: We Are Not Alone
Eventually, I discovered the perfect hub for information and collaboration: the online community known as the B9 Robot Builders Club.
It was here that I connected with a kindred spirit—Michael Joyce, one of the group’s moderators and undeniably one of its most passionate and talented members.
His enthusiasm was infectious, and his expertise invaluable. This felt like a pivotal moment in my journey toward building the perfect replica. But just as things were gaining momentum, an unexpected detour loomed on the horizon—one that would complicate, challenge, and ultimately reshape my quest in ways I couldn’t have anticipated.
Enter… ICONS AUTHENTIC REPLICAS
Much to my delight, during the course of my research, I stumbled upon a remarkable company based in Orange County, California: ICONS AUTHENTIC REPLICAS.
Officially licensed to produce the B9 Robot, their prototype boasted an impressive array of features, and the accompanying photos were nothing short of mesmerizing. The craftsmanship and attention to detail instantly caught my eye.
At the time, I was fully immersed in production work on the television series Millennium, which left little room for prop-building passion projects.
So rather than continue crafting my own version from scratch, I made the decision to purchase one—believing this would still fulfill my childhood dream in a far less time consuming fashion.
Something Was Wrong
ICONS had secured licenses to produce replicas from a myriad of studios and featured an impressive product line of high-quality, replica props and filming miniatures. At the time, it was the biggest company of its kind and seemed well positioned to produce the B9. That said, I'd paid via credit card in order to protect myself. Should there be a problem, I could use a "charge-back" to reverse the transaction, and recover my money. After pre-paying $16,500.00 USD to set my position in the production queue, myself, and dozens of other customers, eventually became alarmed when the company's production schedule had become mired in numerous setbacks. Many months later, after only 3 or 4 examples had been delivered, production had apparently ground to a halt.
By that time, the vague assurances from company President, Jim Latta, seemed hollow… and eventually set-off alarm bells with many his clients, myself included. I even flew out to discuss these production problems personally with him. He extend his personal guarantee that my robot would indeed be delivered. During that same visit, I was taken on a tour of the "Robot Factory".
"ROBOTS BEGIN SHIPPING"
Early on, this optimistic progress report was mailed out to clients. As it would turn out, its claims were terrifically, overly optimistic.
ICONS AUTHENTIC REPLICAS - Orange County, California
Click iImage to View
The facility showed scant evidence of any real production, casting further doubt on Mr. Latta’s credibility. More telling, however, was a subtle comment made by the individual who conducted my tour—whose name I’ll withhold here. He strongly hinted that I might be wise to reconsider building my own robot.
Sadly... It Was Time to Bail
Not long after, I exercised the credit card “charge-back” option and successfully recovered my payment. To my knowledge, I was the only person—besides perhaps one other—who managed to secure a full refund.
Sadly, not long after, ICONS AUTHENTIC REPLICAS collapsed into insolvency, leaving many hopeful enthusiasts without their beloved robot… and out thousands of dollars. A childhood dream, for many, became lost in space.
The ICONS "Robot Factory"
The Dream Reborn?
For a brief time, hope was rekindled. A company called Classics Reborn (operating through the manufacturing facilities of company known as Mannetron) announced plans to pick up where ICONS had left off.
Hope Flickers... Then Fades
Enthusiasts were cautiously optimistic. Yet once again, the dream stalled—only three units were ever produced before the effort quietly fizzled.
So, with resolve forged through disappointment, I returned to my original plan: building the B9 myself. Then, unexpectedly, something intervened.
B9Creations: Michael Joyce Picks Up the Challenge
Production version (#002). Ultimately, only 3 were made.
Michael reached out to ask if I’d be interested in placing a no-obligation preorder through his company, B9 Creations LLC, which had secured rights to produce 250 units. Given his sterling reputation, clear-eyed pragmatism, and unwavering dedication to the prop-building community, I didn’t hesitate.
I was back in the game—only this time, the odds felt different. This wasn’t just another company; it was a craftsman-led mission driven by passion, not just promises.
Back in research mode, I picked up the phone and reached out to Michael Joyce—hoping for technical guidance and eager to relay the turbulent tale of my ICONS experience. What followed turned out to be a fateful conversation. Michael, already a respected figure in B9 circles, revealed that he was preparing to launch production of officially licensed B9 replicas himself.
He asked if I’d be interested in placing a no-obligation pre-order through his company, B9 Creations LLC, which had secured the rights to produce 250 units. Given Michael’s sterling reputation, clear-eyed pragmatism, and proven dedication to the prop-building community, I didn't hesitate. I was back in the game—only this time, the odds felt different. This wasn’t just another company; it was a craftsman-led mission built on passion, not just promise.
Company President, and good friend… Micheal Joyce
Announcement
www.lostinspacerobot.com
B9Creations Replica "Robot"
Geek Minds, Think Alike…
Over the span of several weeks, Michael and I exchanged countless emails and phone calls, diving deep into the nuances of B9 production. He knew of my background in prop building, and understood how invested I was in preserving the robot’s authenticity. Our conversations were always engaging—part technical brainstorm, part nerdy delight.
As production moved forward, I was thrilled to make a few minor contributions of my own. Michael remained thoughtfully pragmatic throughout, often seeking input from fellow enthusiasts when it truly mattered.
One such moment came when I advocated for the use of incandescent bulbs in the “finger lights”—just as they were in the original prop.
"Finger-light" assemblies at the B9Creations factory
In my view, LEDs couldn’t replicate the warm glow of authentic vintage bulbs, and even when switched off, their mere presence would subtly undercut the robot’s retro charm. So, for better or worse, that call was mine!
Special Delivery!
A few scant months later, I was at a nondescript hotel in Washington state waiting intently… for my "connection". This was where Micheal and his wife had agreed to meet with me in order to personally hand-deliver my B9.
After a quick call on the mobile phone, I located Michael in the parking lot and met him face-to-face for the first time. It was great to finally see him in person and chat with him.
I have to admit however, I was also pretty eager to inspect the Robot, which he had transported (practically across the entire US) from his factory, in South Dakota.
This particular Robot, was the last of the original production run of ten to be delivered (serial No. 002). The others had either been shipped by alternate means (to non-US/Canadian destinations) or hand delivered, via Michael's truck/cargo trailer rig. The sides of the trailer had professionally made signage, proclaiming "B9CREATIONS" , with a large, beautifully rendered graphics depicting the B9 Robot… with his bellowed arms waving.
Putting Him Together
The hotel management graciously allowed us to "borrow" one of their meeting rooms in order to unpack and inspect the Robot prior to handing over my cheque. This still seemed prudent, given my previous ICONS experience. Michael understood my cautious nature, and was happy to accommodate me. It was important to him to ensure that the first 10 clients be totally comfortable and satisfied with their purchase. After all, we would eventually be posting reviews on his website and he wanted them to reflect positively on both his product and the customer experience.
"Inspection" basically meant assembling and powering-up the Robot. Three main components were unpacked from separate shipping boxes… the "head", "torso", and "tread" sections. This really was the only practical way to transport something that, when assembled, was approximately 7 feet tall, and weighed nearly 300 pounds!
The hotel staff were constantly circulating around the entrance of the meeting room, wanting to get a look at the thing… chatting excitedly amongst themselves as the Robot took form. I was trying my best to stay focused on task, and convey a business-like demeanour, but what I really wanted to do, was run around excitedly, and invite the staff in to share the experience.
Really, Truly, Impressive
Once it had been fully assembled and plugged in, I was handed the iconic "power pack". "Go ahead and plug it in.." said Mike… and so I did. Immediately everything lit up… motors started turning, I heard whirring and clicking… then the Robot booms-forth: "Hey!… Who turned out the lights!" I was marvelous! I then removed the pack in order to trigger a certain expected reaction. Sure enough, the Robot exclaims a mournful: "Ahhhhh…." and everything suddenly stops… all lights and sounds had ceased…. perfect!.
After reinserting the power pack, Micheal then gave me instructions on how to control the various features. Many of the key functions were accessible through a small, key-fob sized radio remote control. Functions include turning the Robot's torso left/right, directing the Robot's voice to respond "Affirmative/Negative" and activating the Robot's soil sampling sequence.
So Many Cool Features!
When activated, this last feature triggers a precise, "mechanical ballet"… completely accurate to what had been portrayed on the show: The soil sampler door slowly opens from it's location at the Robot's lower-right "tread section"… the core drill extends and starts to rotate. After a moment has passed, the sequence reverses… and the Robot then declares the results of the test. This would change every time this action was completed… sometimes comically, with analyses such as: "This planet composes mainly of carpet, with small traces of dirt!"
Every control on the Robot had been cleverly utilized by Micheal to control the myriad of functions he'd provided. For instance, the knob located beneath the Robot's right arm is a functional volume control to adjust voice playback loudness.
The Robot's soil sampler deployed (as seen on LOST IN SPACE)
Should you slide open the authentically reproduced "Programming Bay" door, there are several toggle switches inside that control functions such as "STANBY-MODE" (enables/disables Robot operation), "MOTOR CIRCUITS SWITCH" (enables/disables motor functions), and the "ALTERNATE AUDIO SWITCH" (this provides switching between the internal voice & sound effects audio, or to an external source, such as an MP3 player). Along with the authentic switches, there is even a small removable reel of ¼" audio tape inside… just as it was depicted on the TV show.
The ten illuminated, rectangular pushbuttons in the centre of the chest also have operational control functions. Each function is initiated either by a single button press or pushing 2 to 3 specific buttons in correct sequence. These functions include, "Soil Sampler Sequence" (as previously described), activation of ten different spoken phrases, activating left or right motorized waist rotation, etc... A truly fabulous utilization of the controls depicted in the original design!
And Talkative Too!
Speaking of phases, the Robot has over 500 of them, recorded onto an internal compact flash card. Often, he'd give a different appropriate response to certain programmed sequences, such as the soil sampler and power pack routines. This kept it interesting, rather than always using a single, standard, "canned" response. Very well thought out functionality.
Sealing the Deal
I was very satisfied with what I'd seen, and happily handed over the requisite bank draft. We all then participated in breaking down the Robot in preparation for the final leg of his journey. When repackaged, the Robot's components barely fit inside my empty GMC Safari van. Thankfully, after some precise adjustment, I was finally able to close the side door!
It was very gratifying to have had met Micheal, and to have received personal instruction on the Robot's operation. We both agreed to stay in touch… and I mentioned, that I would be posting a glowing review. I was then I was off, back to Canada... with my special cargo!
My Fine, B9!
My B9 ultimately ended up in my office as kind of a company mascot. I would always take special delight when somebody would come by and see and hear the Robot for the first time… especially when quite often, the visitor would be greeted by name!
This neat trick was made possible by the voice actor who was the original voice for the Robot, Mr. Dick Tufeld.
Micheal had brokered a deal with Mr. Tufeld to record custom phases for his customers for a modest sum. How could I resist?
You can imagine the look on people's faces when the Robot would addresses them by name… and in the Robot's own distinctive voice! *Priceless*.
Hmmm... "An Intriguing Proposition"
About a week after setting up the Robot in my office, I started noticing little things that bugged me that were manufacturing related. Nothing serious, but because I liked Micheal, and wanted his business to go well, I started giving him feedback on fit and finish issues I'd identified.
I made a concerted effort to present my comments as constructive criticism, and I guess with some success… he never seemed put-upon, and always received my notes with genuine gratitude. That said, he did once say that "I was the fussiest guy he knew when it came to the Robot !"
Some time later I got a call from Michael. He'd been having trouble finding people with the right skill-set to do the finishing work for the Robot's torso component, and floated the idea that maybe my company could do this for B9Creations. Micheal seemed comfortable with this idea, given my critical eye for detail and extensive knowledge of the Robot. His difficulty in finding the right people locally was hardly surprising, given that his factory was located in rural South Dakota. There simply weren't many people available for this kind of specialized work…. so I agreed to give it a try.
My B9—Serial Number 002
My only trepidation, was that we would be engaged in a manufacturing a consumer item… not a movie prop, that only had to look good from certain angles... and only had to last ten shooting-days! We'd resolved that the contract would not start in earnest, until we'd completed at least one B9 torso for our mutual evaluation.
Getting Started
Micheal flew in from South Dakota to meet with my colleagues Bob Boel, Peter Toporzysek and myself, and go over the specs for the torso component. It really only took about 4 hours to receive instruction, ask questions, and document everything necessary to process the sample torso Micheal had agreed to send.
After that, we'd planned to use the remaining time for a short trip to Washington state to introduce Mike to some fabulous attractions there… namely, Museum of Science Fiction and the Museum of Flight.
We all had terrific time! By the time Micheal had left, we were pretty pumped-up at the prospect of our new long-term contract and were now ready to start the evaluation process. This would begin once we received the first "test" torso from South Dakota.
Torso Number One… Come on Down!
Micheal at the Museum of Flight (Seattle, Wa)
Not long later, the first 3 of what would hopefully be at total of one-hundred and fifty B9 torsos finally arrived.
They had been produced for B9Creations by a subcontractor that specialized in the production of fiberglass boat hulls. These had been cast from a set of 4 rigid moulds (themselves made from fiberglass) and were delivered to us with the unneeded material that filled the requisite openings in each torso carefully removed by B9Creations staff.
An Exciting History... and a Bothersome Issue
The set of moulds being used to produce these torsos were derived from an epoxy casting of a torso master that was itself, pulled from the original cast-stone moulds that were made in the 60's by the artisans at 20th century fox.
The Robot's fiberglass components at B9Creations
Interestingly (and significantly), these would produce torsos that were, for all intents and purposes, identical to the original one occupied by performer Bob May during the production of LOST IN SPACE.
While this fact suggested a more authentic finished product, it actually revealed an issue that required thoughtful address... namely, the numerous defects apparent throughout the original torso.
(For more on the history of this iconic prop, check out the Wikipedia entry for the B9 Robot.)
The Devil in the Details
When LOST IN SPACE was originally broadcast, televisions had relatively small screens, and were unable to display much detail.
For this reason, props that have survived from the series do not exhibit the fit & finish one might expect. In fact, they can appear rather crude by modern standards… and the Robot's torso was no exception.
The original stone moulds produced in the 60's
For this reason, props that have survived from the series do not exhibit the fit & finish one might expect. In fact, they can appear rather crude by modern standards… and the Robot's torso was no exception.
Finishing detail of the restored original Robot
B9Creations torso detail
Lines intended to be straight… weren't. Details were not crisp, and aspects requiring symmetry, were not well rendered… and the painted finish was extremely rough and very uneven in texture.
Micheal had decided from the start, that customers would not accept this level of fit and finished in an item retailing at $24,0500.00 USD, as it would simply be interpreted as subpar manufacturing… even though this is exactly as the original prop had appeared.
Given this, his goal was to preserve the character of the original prop as much as possible (as people remembered it) while exhibiting a modern build quality.
Evaluating the Job
Getting down to the business of evaluating the viability of a long-term contract really hinged on what we'd learn by processing a sample torso. After that, I'd have enough data to make an informed decision. But first, my colleagues and I would have to determine what tools and techniques would yield the best result... and as efficiently as possible.
Mould-line artifacts would occur (flashing and mis-alignments) wherever the mould sections joined. These had to be carefully ground down, sanded and fille as required. There were other mould artifacts, like bubbles and sink-holes, but mould-lines were the most prevalent issue requiring attention.
Besides basic clean-up, there were several specific processes required to accommodate the installation of other components. This would occur in-house and at the B9Creations factory. Initially, we identified 10 distinct processes that were necessary to achieve this and our target level of fit-and-finish.
Bob, Pete, and me, with the "test" torso …ready for paint!
This Was the Fabrication Process List
- Boring out holes, to accommodate mounting of the 12, "chest light" indicators.
- Providing a cut-out for the "chest button" assembly.
- Drill and countersink small holes, to accommodate fastening of the "chest button" assembly.
- Grinding of the interior areas adjacent the vent opens, to accommodate precise fit of the vent assemblies.
- Attachment, and seam-filling, of two aluminum roundels to either side of the centre-chest. A drilled through-hole in the centre of each, was also necessary. This was to accommodate mounting of the volume control / microphone components, into the centre of each rondel (at the factory).
- Mounting holes and attachment, of two, wielded-steel, "torso hooks".
- Flush-mounting of three, ⅛" phone jacks on the right-side of the torso, to accommodate "power pack" attachment and removal. These were bonded in place with polyester body filler, then filed… precisely flush with the torso contour. Each jack opening was then carefully chamfered with a countersink cutter.
- Mounting of a microswtich assembly, behind one the "power pack" jacks. This would be later tied into control electronics at the factory, and would trigger certain effects, whenever the "power pack' was removed or replaced.
- Removal of irregularities along the edges of all openings.
- Scratch, and tooling-mark removal.
The Very Specific Paint Finish Required 4 Additional Processes
- Several primer coats… sanded-out.
- Two coats of "texture-coat"… lightly sanded.
- Silver finishing coat.
- Masking and application of gunmetal to the centre-chest area.
With That, We Now Have a Plan
Combined, fourteen different distinct processes were required to ready a B9 torso for final assembly in South Dakota.
After reviewing these processes we determined that with our manageable setup expenditure, the contract would prove to be within our scope, and profitable.
From a shop standpoint, this would require partitioning off an area to contain the airborne particulate from fiberglass grinding process, upgrading the shop compressor to one of higher capacity, purchasing a few new air tools and obtain some personal protective gear.
After Micheal signed-off on our initial "test" torso, we were ready to gear-up for production.
Our painter Ron Scott, with the first 3 completed torsos
It Begins: Processing Torsos For Replica B9 Robots
Our crew were able to immediately apply what we'd leaned during the testing phase, to our production phase, with little difficulty. As expected, we were quite comfortable processing four B9 torsos at a time... with very good results.
Once completed, I would careful photograph each, noting any issues that might merit closer attention in the next batch, and re-crated them for return to South Dakota.
Micheal, was quite please with the first run, and immediately shipped the next four torsos for processing.
Grind, sand, fill… REPEAT!
Slideshow: Images Depicting the Torso Processing and Completed Robots
The Best Laid Plans…
It only took the inspection of the next four torsos to arrive, to realize a serious problem. In addition to correcting the numerous anomalies expected in each casting (characteristics of the original master torso) there were now a rapidly growing number of significant defects appearing, due to the gradual breakdown of the moulds. This issue was beginning to contribute more and more, to the amount of time required for adequate processing.
By this time, about 50 torsos had been pulled from the moulds… and they were already degrading to the point that, if not soon replaced, we'd be spending way more time per torso than planned for. This would significantly cut into the bottom line, as well as delay delivery of processed torsos to South Dakota. I made a note of this to Micheal, and said we'd have to closely monitor this issue. He said that he would be creating new moulds, as soon as it was practical to do so.
It was shortly after that, Bob Boel announced that he'd have to leave the team, for personal reasons. Unfortunately, I'd really not considered this possibility, and was really not prepared for its impact on operations. Not only was the job becoming gradually more challenging with each new casting received, but now I'd lost one of my most skilled colleagues. He was however, able to remain, until we'd completed two more units.
Bob would not be easy to replace. Moreover, the torso processing operation had not yet shown a profit. That meant, in order to maintain cash-flow, I was still busy with established TV and movie clients, while supervising the torso operation, as well as working on them myself. Given the prevailing obligations, finding and training someone suited to the work, proved to be a nightmare. It was with great reluctance, that I called Micheal to decline further participation with B9Creations in this endeavour.
Although obviously disappointed, Micheal wasn't upset. He seemed grateful for what we had managed to deliver, and was sympathetic of our situation. As it turned out, only two of the four current torsos were ready for shipment. In order to mitigate the situation, I volunteered to disassemble my personal B9, and include its torso in the return shipment (I would retain an unprocessed torso for future completion). Micheal didn't see this as necessary, but I knew I'd feel better, if I'd made the gesture. On that somber note… we both moved on.
Long-time friend and colleague, Bob Boel
Happy Endings
To date, Micheal has delivered 62 completed B9 Robot replicas, at the price of $24,0500.00 USD each! Should you go to his website's "Testimonials" page, each and every one of those customers who posted there, is thrilled with the quality and authenticity of Micheal's efforts. (He is still building B9's, but now, by order only.)
Micheal also eventually produced a new set of moulds for the B9 torso, derived from a new corrected master. No more correction of original defects on each new casting, would ever be required again! Moreover, these new moulds include the torso interior, so that there is no longer any need to extensively modify the inside to accommodate component installation. They're also faster to make, as they are now cast from a high-strength resin, rather than the being laid-up from fiberglass.
B9 Creations Becomes a B9Creator
Interestingly, Micheal's company has now also branched out into producing an affordable, high resolution, 3D printer called the B9Creator… a fabulous, world-class machine!
B9Creations new venture… hi-res, 3D printers… the B9Creators!
Although we were unable to continue work with B9Creations on the Robot torso contract, it was rather gratifying for the crew to know that at least seven happy B9 customers were enjoying our work. The expenditure on new tools and equipment proved to be extremely useful in our regular prop building operations, and were quickly amortized.
Best of all, Micheal and I are still good friends, and still stay in contact… albeit, much less frequently.
We did however participate on piece by Joanna Sailor of NPR titled "For Sale: 'Lost In Space' Robot Replicas", which chronicled how and why Micheal decided to build replica B9's. It was terrifically fun to do, and I was happy for the exposure it would provide his company.
As for my B9 Robot… Peter and I are in the final stages of processing his new torso… and this one's going to be PERFECT! With any luck, he'll be greeting my friends and colleagues by Halloween!