Re: Could Ryan's second set of powers been used to create a fourth VR Trooper ?
 

I doubt it since the only MOTDs to show up in American footage were Dark heart, and Combax, and even then Saban merely made their own suits for them.

Re: Could Ryan's second set of powers been used to create a fourth VR Trooper ?
 

I don't remember Combax but I do kind of remember Dark Heart, just not his design. But I do agree with you. I doubt they had any suits left over to begin with considering Ryan's 2nd suit came from Shaider which aired in 1984.
Kaitlin and JB's suits came from the '86 series of Spielban.
Ryan's 1st suit came from Metalder, the '87 series.

So personally I would find it highly doubtful that Toei could send then anything at all that would still be usable.