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Onyx said:
And then a little later you say,
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This is what happens when you don't finish a post up right away. Just reread that as "the armor system is mostly right" and it all fits together.
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Onyx said:
The AI isnt using the armour you have now anyway. Simplify it and make it race based and the AI will be more competetive and interesting. I'm not totally sure on this but arent there a limited number of AI tags. Gonna use them up pretty quick this way when they could be saved for other things.
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There are plenty of AI tags to go around. Any ability that does not work serves as one. The "AI Tag" abilities are a rather recent (1.91) feature.
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Onyx said:
Were they misinformed or did they have a different opinion...
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They did not understand how the armor system works. They were misinformed. I don't blame them; it isn't documented very well in the current version of the mod.
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Onyx said:
Never really played the stock game so I dont know how that works.
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You really should play at least one game of unmodified SE4 to put it all in perspective...
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grumbler said:
The AI cannot use structural suports because they have no weight and you have to give the AI design parameters by weight (or tell it to use just one, which would be silly).
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Not quite true. The parameters in the design file have no relation to the size of the components. Tell the AI to add 1 Structural Support per kT of ship hull and it will definitely do so. You might need to add this requirement near the beginning, as I am not sure when exactly the AI stops reading the misc ability list.
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One way around this is to size armor for the hulls, making each armor worth, say, 5% of the hull size, and scaling using mounts (as is already done for engines). Another way is to create some larger armor components. However, I don't now how either solution would affect the "leakiness" of the existing armor, so I am leaving those considerations for the end of my analysis and hope someone else solves them in the meantime! 
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They could have dire affects. Armor would behave quite differently on different sized hulls. In my assessment, each leaky component (of the same class) should have the same size and hit points. Another option would be to remove the tech grid aspect. This would enable each level of armor techs researched to have a significant gain, rather than a very minor, very costly (in terms of retrofit cots) gain. Tech grids are nice, but bewildering, and out of place when there is only one thing in the entire mod that has a tech grid, in my opinion.