It looks like this is why Oda has never previously drawn Sanji using coating on his legs, so that he could save the black leg Sanji reveal for conquerors haki.
Curse from Davy jones which would explain his anger towards him.
Or
He almost died against Joyboy and underwent immortality surgery within MJ and in that room or place he basically operates as if he was in pristine condition but when he leaves the room he slowly degrades to his mortally injured self.
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