An ironic case. Jason Geiger earned the Stage Name Austin St. John (inspired by The Six Million Dollar Man) as his agency thought it wasn't a strong name... and he ended up playing a Bad Ass called Jason. According to Tommy's actor Jason David Frank however, it was due to a disagreement the two had when they first met backstage.
Dawson Casting: Do you honestly know any highschoolers that look that old? Well, out of the original five, Austin St John was 18 and Thuy Trang was 19, but Walter Emanuel Jones and Amy Jo Johnson were 22 and David Yost was 24. It would have been much more believable if they made them in college.
Made worse by the fact that the characters were retroactively de-aged from seniors to freshmen after the first season was a success. Originally Austin St. John and Thuy Trang (and Jason David Frank (19 at the time)) were going to be plausibly the same age as their character.
The second season wasn't as bad, but still fairly notable. Of the four (including Kat) replacements, Johnny Yong Bosch was 18, Karan Ashley was 19, Steve Cardenas was 20, and Catherine Sutherland was also 20. Add in the remaining 2, and you get another 20-year-old (Jason) and a 25-year-old (David). Before Kat, however, Amy was 23 and still on the show.
It wasn't just the rangers who suffered from this. Bulk and Skull were played by actors aged 23 and 19, respectively. It showed.◊
Direct-to-Video: Alpha's Magical Christmas, Lord Zedd's Monster Heads and The Good, the Bad and the Stupid: The Misadventures of Bulk & Skull.
Executive Meddling: Not of their own choice but parents found Zedd to be too scary at the start (who could blame them, in the introduction in addition to his appearance. The guy had a snake wrapped around his arm.) Thus, the producers had to tone him down later to make him more of a laughable villain. It wasn't too much to dampen his character as he was still a force to be reckoned with however.
Lost Episode: The original Pilot for Mighty Morphin' Power Rangers was advertised and presented as such on Fox Kids. Notable changes include the casting of the Yellow Ranger as Audri DuBois as opposed to Thuy Trang, Zordon being known as "Zoltar", and the Zords being referred to as "Droids".
There's also a second variation on the pilot, which Tony Oliver shows exclusively at conventions.
Mean Character, Nice Actor: Bulk and Skull are two terrible bullies, but their actors (Paul Schrier and Jason Narvy, respectively) are said to be some of the nicest and most fun guys you could ever hope to meet. One PSA even did An Aesop rather effectively about this. Of worthy note is that as the show goes on, Bulk and Skull go from being annoying jerks to comic relief, and as time passes even further, they go from okay guys to actual heroes.
In a bit of a subversion, there's Tommy Oliver. While a nice guy and not a villain proper, he is quite famous for his dark beginnings, where he was brainwashed into being mean, rude, and very cold. The actor, Jason David Frank, is just as nice of a guy (if not moreso) as the character he (normally) plays. It's worth noting that in later seasons, his character strikes fear into Bulk and Skull, and becomes more and more of a gruff stoic. Meanwhile, his actor is up at panels cracking jokes and relating funny stories to his fans.
Zordon was voiced by David Fielding until "Calamity Kimberly", when Bob Manahan took over from "A Star is Born" onward.
The switchoff is notably different: Fielding used a terrible, cheap imitation of a British Accent, possibly to make Zordon sound more sophisticated. It's worth noting that Fielding was the one whose head we always saw as Zordon.
Rita's suit actress would be played by Carla Perez in season 2 with Barbara Goodson still providing her voice, in order for Rita to appear in American footage. Scorpina as well in "Goldar's Vice Versa" played by Sabrina Lu .
Lord Zedd was voiced by Robert Axelrod in the series, and by Steve Blum in the 2007 Playstation 2 video game Power Rangers: Super Legends.
The Other Marty: Audri DuBois was originally cast as Trini in the original pilot. Also Skull was originally played by an actor other then Jason Narvy; while he was not named in the pilot, his biker attire and crush in Kimberly identify him as the same character. However, Bulk and Skull's personalities were reversed in the pilot.
The Pete Best: Brad Hawkins was originally set to play the White Ranger, who was originally intended to be a new character separate from Tommy the Green Ranger. Due to Tommy's immense popularity on Power Rangers, Tommy was instead written back on the show as the White Ranger, while Hawkins was given the lead role on VR Troopers, which was originally intended to be a vehicle for Jason David Frank.
Postscript Season: Season 1 after "Doomsday". It was supposed to end with a shot of the Rangers sealing Rita away again, and is why Tommy makes a cameo appearance at the end. Most of the rest of the season was new footage created by Toei specifically for Power Rangers.
Prop Recycling: Old monster suits were often reused and altered in some fashion to create new monsters.
Mr. Ticklesneezer was painted blue and dressed in a Santa Claus-like outfit to become Grumble the Elf (who was more of a friendly elf creature rather than an evil monster - but then, so was Mr. Ticklesneezer).
Chunky Chicken had his feathers plucked and had armor and a helmet added to become Turkey Jerk.
Grumble Bee had his red sections painted silver and was given buck teeth to become Waspicable (a peaceful monster who didn't want to harm anybody) in Power Rangers in Space.
Pirantishead, RoboGoat and Turbanshell were repainted and had a bunch of crap added to them to become random alien monsters in an episode of Power Rangers Turbo.
Primator was painted whitish and had extra fur added to him to become the yeti-like Snow Monster.
Salaguana was chopped into little bits and used as reptilian armor for Triter, a heroic alien warrior from Power Rangers Zeo.
Silver Horns was painted green and oddly had a tongue added, since he didn't really have a mouth, to become Repellator.
The Wizard of Deception's rat monsters were actually leftover, unused suits from the movie that were replaced by the Oozemen.
Inciserator was made up from the head of an unused Kakuranger monster and the body from Merrick the Barbaric (whose own episode hadn't even aired yet).
Tube Monster was Pipebrain repainted white and blue, but that is actually from Gosei Sentai Dairanger to show the cycle starting all over again with an almost identical type of monster.
Schedule Slip: Because sports always pre-empted the show (in some time zones at least), the "Green with Evil" airing inserted long hiatuses between episodes - the five-episode miniseries lasted over two months. And then the FIFA World Cup put the show on hiatus for yet another month.
The last four episodes were pre-empted on the West Coast for Little League. They can't be shown at a later date, because Nickelodeon took over the broadcast rights before the episodes could be re-scheduled.
Suffering For Your Art: Voice actor Barbara Goodson was getting jerked around by Saban during pre-production. She was given the part, and told to voice Rita like the Wicked Witch. She did, and was fired. They decided to try to make Rita sound angrier, and rather than let Goodson try, they forced her to reaudition. According to her, she did, and said, "You want angry? [Rita's screech comes out of nowhere] I'LL SHOW YOU ANGRY!" Not knowing she would have to do the part for seven years. She mentioned going through a lot of water and cough drops, and we thank her for suffering through.
You Look Familiar: Series Write Doug Sloan played Kimberly's Uncle Steve in "Foul play in the sky" and her mother's new boyfriend in "Return of an Old Friend" its somewhat popular in fanon that they're the same person and Kimberly's mother left him for his brother.
What Could Have Been: At some point before Season 2, there were plans to introduce new versions of the Dinozords, as well as various different takes on the White Tigerzord (as can be seen by these pieces of concept art from a Super Sentai Giant Robot artbook). These plans were aborted when it turned out that adapting mecha footage from another Sentai proved to be more economical for Saban than commissioning Toei to make more new footage for them
A redesigned version of Titanus the Carrier Zord was also planned to be introduced for Season 3. Various concept arts◊ were drawn, but Titanus was left mostly unchanged in Season 3 (aside for the addition of the Dragonzord's chest plate, since the Dragonzord was absent during Season 3). Some of those designs were made for Power Rangers in Space, and indeed a "Space Titanus" toy was in fact released, though it was never used in the show.
A Samuraizord, shown in the same image above with the Titanus redesigns, was considered for the second season as well. The Samuraizord would've been very similar to the Red Dragon Thunderzord, in which it could transform between a Tyrannosaurus and a humanoid robot. Another reject concept art shows a robot that was formed from three bikes.
Dan Southworth (Eric Myers on Power Rangers Time Force) stated at Power Morphicon that he had auditioned for the role of Adam back during production of the second season.
At one point the writers actually considered having Goldar eventually overthrow Rita instead of creating Lord Zedd
Jonathan Tzachor, a producer on the show and big fan of Super Sentai, wanted Tommy to die just like his sentai counterpart, but he was overruled presumably for BS&P reasons. Seeing how Tommy's popularity was a huge contributing factor to Power Rangers becoming popular enough to exceed its original order of 40 episodes, this was probably a good thing.
In earlier scripts, Tommy was going to be a biker named Rocky.
Initially there was a completely different idea of adapting Zyuranger. The show would be called Galaxy Ranger (which was Zyuranger's international title) The characters were going to be: Victor Lee (Red Ranger) is an asian martial artist. Zack Taylor (Black Ranger) is a detective with an attitude. Kimberly Harte (Pink Ranger) is a clumsy aerobics instructor. Billy Cranston (Blue Ranger) is an athletic heartthrob with a body of steel. Trini Crystal (Yellow Ranger) is a struggling, white novelist.
The original finale (written before the show took off) would have seen Rita crashing the Ranger' senior prom; Saban was even looking into bringing Machiko Soga over to the States so she could physically interact with the Rangers at the Juice Bar. It would have ended with the rangers Storming the Castle after getting access to Rita's spells and Jason reciting an incantation to seal her away, but the show continued after it was a hit. Tommy's cameo was a relic of this original plan as...
Jason David Frank was going to be in VR troopers (called Cybertron at the time) and shot a pilot of it. After Power rangers was picked up for more episodes Brad Hawkins was cast as the White Ranger, Saban decided that it was too risky to replace Frank now that there was the opportunity to bring him back, so Hawkins went onto VR troopers and Frank returned to Power Rangers.
Ernie was originally going to be Zordon in disguise, watching over the Rangers from the Juice Bar.
"Goldar's Vice-Versa" wasn't going to be Scorpina's last appearance, as there were plans for her to return later in Season 2. However, chiefly, the failure to secure the American actress for more than one episode led to abandoning those plans.