^Dairanger image. Any shots you see with the white ranger and, the other rangers in Power Rangers is footage shot by Saban. As for when they started shooting footage with the rangers suits/monsters for power rangers. Well in different drum there's some footage shot with the monster getting the girls into the trap. In Peace, Love, and Woe there's some shots of the ranger's in their suit. Production wise it could've been started at the beggining. Since, Tommy and, Thuy's Trini was casted at the same time. Jason David Frank was actually in the suit fighting Austin St. John in Rita's dark dimension. Jason David Frank talks about that fight here.
Gaffer Tape: I'm not really sure it'd be noticable from an editing point of view. Considering they still had the actor for Zordon. All they'd have to do is get him to read another line. The only thing that kind of gives it away is Jason's attitude about the situation. He not only doesn't acknowledge that Zordon gave away his leadership. He outrightly says "This is great!"