[AkibaSilver]

It depends on the season as to how "Original" you wanna be, but yeah, generally the non-suited stuff plus some suited footage (the zord interiors, shots with the some actors demorphed) is all new, with the fight scenes intersersed but recontextualised (as much as you can recontextualise 'spandex heroes whale on villain").

EDIT: Oh! There are a couple of wholly original footage stories - I think both tie Dino Charge and Ninja Steel openers were purely New Zealand based.

As for Orion vs Gai, ain't it interesting how Gai is the only human on a team of aliens, but Orion is the only alien on a team of humans?