The master of the Power Rangers, Zordon was a floating head in a tube. For the first season, actor David Fielding lent his voice (later replaced by voice actor Robert Manahan) and likeness (kept throughout the run of the series) to the almighty being. How exactly did the producers pull this off? With a razor and a green screen.
Fielding: When I was told that I had the part, they told me to shave my head. I had no idea where this was going, but it was a paying job and I hadn't been in Hollywood very long. I figured it would grow back. Still, when I showed up for the first day of the shoot, I asked why I couldn't wear a bald wig. They said it would look funky. So they glued my ears back, darkened my eyebrows and stuffed them into an arch, and I sat in front of a green screen for six hours.
The Tommy and Kimberly Love Affair
Tommy was the new transfer student and Kimberly was Angel Grove High School's resident popular girl. Sparks flew. However, after the Power Rangers' nemesis Rita Repulsa cast a spell on Tommy to turn him into her evil Green Ranger, he broke Kimberly's heart with his cruelty. Fortunately he broke the curse, but left Angel Grove as soon as he lost his powers.
But not for long. In the second season, Tommy reappeared like an angel from heaven (or really, Alpha 5's lab) at the Command Center to a still-smitten Kimberly.
The relationship between Kim and Tommy was a risk for a kids show, but I think it helped make the show more real. —Jason David Frank
Levy: I can only speak from my point of view at the time because I wasn't the only person making every decision about everything. The show evolved and we found out that the kids that we thought were well past the age of wanting to watch Power Rangers were still watching it. The 12-, 13-, and 14-year-olds. By then, you're entering a whole new arena of pre-teen, which is when you start crushing. We had to stop hinting at the relationship and deal with it because the characters on the screen were in high school but they looked like they were in their 20s.
Plus, the characters became so familiar with people, with kids especially. They were like their friends, so they had to make the stories a little more personal. They needed subplots about what was happening with those teens outside the suits.
Johnson: I was excited to have any sort of storyline. I just wanted to act, and the more plots the merrier. Jason was a pretty charismatic kid and any good reason to be able to flirt was fine by me.
Frank: The relationship between Kim and Tommy was a risk for a kids show, but I think it helped make the show more real. It was something older kids could relate to and sparked their interest. It obviously worked since it became incredibly iconic.
With her husband Lord Zedd, Rita Repulsa was every Power Rangers fans' most feared villain. The alien witch, hellbent on world domination, had control over an unrelenting army, known as the Putties, and a wicked sidekick named Goldar who followed her every command. Not to mention, she had the power to mold monsters (fashioned by her in-house scientist, Finster) and grow them to the size of skyscrapers. But most memorable of all, she had catchphrases for whenever her evil was a-brewin'.
Goodson: "I've got a headache" might’ve come from mimicking what the actress was doing in Japan, where she was holding her head. One of the writers could’ve come up with that. But it fit and we’d find a way to stick it in when Carla was Rita. It became a slogan. She had a couple of them: “After 10,000 years I’m free” and “Make my monster grow.” People ask me to say those every time I do a convention. I have to tell them to wait ‘til the panel.