On Gears Judgment I think they should consolidate the Locust character selection and allow you to select the armor from them instead of having them as individual characters since they are so similar.
From a development point of view I would say that their current setup with the Drone variants is inefficient because the cooking process works in such a way that they have to have lets say a Drone's skeletal mesh cooked with each type of variant of Drone (Miner, Cyclops eg) just for a simple helmet addition or shoulder pad. From your point of view you could be like "But what if I wanted Miner's helmet mixed with Spotter's shoulder pads on a Grenadier's body?" and this is possible if they went the route of modular pawns that they did with UT3.
In their current form this isn't possible because they don't use modular pawns (Which allows the player to choose armor attachments and what not). But if they did this you could choose between a Grenadier Beast Rider or a Drone Beast Rider and everyone's happy and in the end result you've got more room on the disc because the Drone or Grenadier skeletal mesh isn't being cooked 6 times over or whatever so there wouldn't be multiple copies of the guy.
The people suggesting stuff like Shirtless Kantus, the armor system doesn't work like that since the Armor for Kantus and Myrrah and what not are hard attached to them as part of the model. The Drones use separate meshes for armor and helmets though and the Therons use separate helmets too.