I think when he plays the Green Ranger again in one of the future anniversary episodes it's the "proper" design. From what I understand here the Dragon Shield got damaged in transit between Japan and the US so they had to make a replacement in a hurry.
Unless that is footage from a Sentai as well? I gather later Power Rangers struggled with using footage from crossovers where more than one character in the original scene would be Tommy in their version (IIRC one special especially was hacked to stop multiple Tommies all over).
No they definitely got better at building suits and making their own battle sequences. Even some Zord battles.
I’m not sure the Tommy problem really kicked them like that, they didn’t have a crossover between the Zeos and the Turbos which is the only place it would have really been a pain. (Even then there was a second non-Tommy Turbo Red)
Forever Red is all-US footage and has Tommy!Red Zeo, TJ!Red Turbo, Andros!Red Space…it turned out pretty perfect even though those teams all overlapped
The Sentais started a yearly crossover tradition that PR used or ignored as appropriate—it gave us the well-regarded Alien Ranger / Zeo Ranger crossover, but I believe the infamous In Space / Lost Galaxy crossover was almost all US footage. (They used Psycho Pink as the villain and killed LG!Pink)
This is the one I was thinking of. That's a much better Dragon Shield than was used in MMPR. I dunno if there were any potential other "Tommys" in the background (maybe a White Ranger?)
If there were any shots from Gokaiger that would have been an issue they would have been quick cuts, easy to leave out.
IIRC the Legend War didn’t include a lot of Sixth Heroes in the original shots, they weren’t really involved in the story till Gokai Silver came in, so no errant Dragon Ranger or Kiba Ranger shots. And since TJ can become the Red Turbo Ranger, the only big no-no is Red Zeo + Black Dino Charge Ranger
At this point Tommy has a “Master Morpher” that freely accesses any of his prior transformations It’s not clear what advantage most of them have over each other, but they sure look cool