Hm, let's see...

1) Because he's a crappy character.
2) Didn't they do that for a comic pack already? And, like, very few people voted on it?
3) No. Because 1987 proved to us that no one wants to see GIJoes in their dress uniforms.
4) Uhm, no. Those Red Shadows sucked.
5) Using what molds? No figures in 6-packs ever use original molds, except for new heads.
6) That's kind of costly and complicated for a toyline with such a niche demographic (face it, GIJoe isn't exactly the hot thing right now)

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RIP Minouche, 1994-2009.