Ford clearly doesn't know anything about the show, as you note or he'd be aware that "Chrysalis" was filmed #12. As for "Babylon Squared," which you mention...again, there's something interesting in timing here, which of course Ford will ignore, because he's a pinhead. B2 aired long, LONG after the O'Hare conversation took place. Months.
Now, if we really intended to change the story, if Sinclair was never to show up again, it would have been absolutely simple (since we were still plugging stuff into that episode up until a few weeks before it aired in August) to either snip that scene out, or re-shoot it with someone else. It's a thirty-second shot, absolutely no problem. But we didn't. We left it in. (And we've left other mysteries unresolved, we could've gotten away with it.) We were about five minutes over in that episode, and there was plenty of stuff we could've stuck in to make up the time. But, again, we didn't.
But naturally, none of this will matter to Ford, who is simply an idiot.
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