The Battle With Vulcanilax

KO-35 is not Vulcan. 
You're right, because, if you attempt to make KO-35 look like Vulcan, then Lord Zedd and Rita Repulsa will create Vulcanilax. 
Vulcanilax was wreaking havoc in Angel Grove Park! The Kakurangers, the Hana Rangers, Guardian Warriors, Dragon Ninjas, Sailor Moon, the Sailor Scouts, Tuxedo Mask, FalconMan, StarGirl, JaguarGirl, the Beetleborgs and Shadow Borg battled Vulcanilax, but they needed help! So Zordon and Alpha 5 summoned the Power Rangers to the Command Center! The Rangers saw what was going on in Angel Grove Park and they morphed into action! The Power Rangers said “We need Thunder MegaFalconzord power, now!” Thunder MegaFalconzord swooped into action! Thunder MegaFalconzord battled Vulcanilax! With a swing of the mighty Zord’s sword, Vulcanilax was destroyed! Angel Grove was safe once more! Thanks, Rangers!