I've posted this once before but not on BZP.
We know that Zaktan didn't get killed when The Shadowed One blasted him with his eyebeams. In a recent Ask Greg, he said that was probably because he was mutated. We also that Zaktan was a slave at a protodermis mine before he was a Dark Hunter, and protodermis can transform a person. My theory is this: What if, on the day that TSO came to that mine, there was a freak accident at the mine, and Zaktan got hit with protodermis? The protodermis would have changed his molecular level rather than his armor (I don't know if protodermis could do this, but I see no reason why it couldn't). This would explain why TSO chose Zaktan to join the Dark Hunters, because TSO knows that protodermis would make him stronger and a valuable hunter.
How does the fanbase feel about this theory? Do you agree with it?