Before Malone got the axe, he'd intended to pair Rachel #3 (I think?) with Drew Buchanan as an interracial couple beset by Becky Lee, who would return as Drew's mother but now be a bigot for no apparent good reason to do a story that was already old hat at that point. I believe he also intended to have Rachel kill R.J. in a murder mystery. I'm very glad none of that came off.
Allegedly they considered no less than Eileen Davidson for a Gabrielle(!!) recast in 1991 or 1992, something that blows my mind.