In the scene reintroducing Alpha in "Once A Ranger," Alpha implies he hadn't been in working order for a while. Who's been working on him to get him up and running? Adam, who had experience with Morphin' era tech, and Andrew Hartford. Who created an Artificial Human. Who better?
The Morphin Grid is some sort of energy formed from the battle between good and evil, and the run-off energy tends to form in explosions. With multiple bad guys (and later in the team-up episodes, multiple good guys), the Grid must've been overloaded and gone crazy with the explosions. Considering RPM's explanation for these explosions, perhaps the equivalent of RPM's "bio-channels" got clogged up because of all that.
The seemingly fridge-logical aspect of Andrew making his robot son a young adult in appearance shifts to brilliance because when he finally dies, Mack can live on his own and not be discovered by an adoptive parent.
Ronny being the only one to power the Fearcats' machine seems like just a lazy way of writing around GoGo Sentai Boukenger footage. However, Ronny is an Identical Stranger (possibly reincarnation) to the Goddess Freyja. Who better to drain power from than a supposed Physical God?
The final battle between the rangers and the powered up Flurious makes very little sense, there's no reason Mack not being human should have allowed him to overpower the Corona Aurora, UNLESS Flurious' wish on the Corona has actually been that no human could defeat him? Mack defeating him suddenly makes more sense, the Corona Aurora played Jackass Genie and gave Flurious exactly what he wished for and ONLY what he wished for. Fate then threw the ONE ranger who could beat him at Flurious.
Of course Fireheart's scale would become a mini-Battlizer. Fireheart is technically one himself.
Since Mack is a robot, he won't age like those around him. If Andrew had died before telling him who he really was, Mack would never know why this was happening. Not every day you see a teenager filling up the fridge like this...
