Story wise i'd say no, game staying alive wise I say get everyone you can. We'll work them in somehow. You could just say that Tommy didn't find enough 'worthy' candidates to give all the suits out.

Or perhaps there was a second ship and someone else unearth it and the AI Demetria. Or something.

Wasn’t Rekker going to submit a character?

But to actually contribute:

I reckon we start as is. We can always come up with excuses to add more people.

Another idea: perhaps Zordon can make more nanosuits, but it requires something. Maybe two or more of the Rangers have to "donate" part of theirs. I imagine the suits are capable of self repair, so if they donate some of their nanites, they'll be weakened temporarily, while a new suit "grows" in its own capsule.

EDIT: we would need to bake in some kind of excuse for why he hasn't just been making spares. Maybe it needs a sentient being to bond with before it can grow and/or repair?

Wait, Captain.

Sa'Cha is going to witness the Rangers get their suits and report back to Udonna? How are we playing that part out? He's going to be at the bake sale as well flirting with Finn and minding his business as instructed.

@WindsOfFate Actually, it might just be easier to have Sa'Cha be a full Ranger from the beginning like everyone else. You could choose an actual Ranger-like appearance for him, and he could change between his Sorcerer and Ranger look or fuse them together for a temporary power up. That way he's a full member of the Ranger team right from the beginning.

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So, do I need to change the picture in his profile cause I'm slightly confused, but I'll get over it.

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No, you don't need to change anything about the existing information, I just meant adding Ranger-specific stuff to what's already there. Alternatively, if you don't want him to be a Ranger at first, he could still be there when they find Zordon's ship but he doesn't get bonded to a Nanosuit. I only suggested otherwise so that he wouldn't be the only one present to not be chosen by a suit.

That's of course assuming you want him to be underground with them to directly observe them getting the suits. Like I said, you can also just have him sense the energy from back up on the surface.