Well, my idea for the Dino Minder, and how it was reconstructed, was that after the explosing all that was left of the Dino Minder, the Zero Prototype Suit, and TopGaler was a single white gem (yes I'm taking plot elements from Dino Thunder). So to create a new AbareKiller, Daemos found someone that was compatible with the Zero Prototype Suit, Burai, and and inserted the gem into his arm.
So TopGaler is already bound to Burai, it's just that his mind is fractured so he can clearly communicate. I'm thinking TopGaler should regain consciousness either right before or right after Burai acquires Dino Guts. Maybe have TopGaler take control over Burai's body at some point, and if the time comes when he needs to have a physical body, if we ever use zords, Burai would have to use that technique that the Gekiranger use to bring out their zords.