Nice sound quality and that's one cute robot character from the 1986 film Short Circuit, unfortunately there are few issues: Got one missing quotation mark inside the UTCustomChar.ini shown in red text cause the character is not listed in the customization menu (only listed for bots at Instant Action work):
Code:
+Characters=(CharName="Johnny 5",Description="<Strings:Johnny5.CharLocData.Johnny5_Description>",CharID="Johnny",bLocked="false",Faction="Liandri",PreviewImageMarkup="<Images:UT3_Voice_Johnny5.Taunts.Johnny5>",CharData=(FamilyID="JHNY5",HeadID="C",TorsoID="B",ShoPadID="C",bHasLeftShoPad=true,bHasRightShoPad=true,ArmsID="C",ThighsID="B",BootsID="C"))
...and also can't see the portrait of Johnny 5 inside the Liandri faction because you're using a TEXTUREGROUP_Character from the LODGroup drop-down menu (through UnrealEd), use TEXTUREGROUP_UI instead. In other words, great VP tested for bot gameplay. 
EDIT (05-Jul-2012): add one more missing line in red text.
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