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 [i]can[/i] 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?