Here is another of those ideas which I don't seriously plan to implement, but which might be fun to think about. GearHead's construction system is based on an unholy amalgam of Mekton and Battletech. It's effect-based, which is great for flexibility but not so good for consistent tech levels or in-game tinkering.
Start from the engine up
The engine isn't all that important currently- aside from a few custom types, it's basically just a critical target. This is a bad thing since in the source material engines are very important. Instead of building a mecha from the top down, what about building one from the engine up?
Engines could have a power rating. A certain amount of power needs to be used for maneuverability. The MV score of a mecha would thereby be based on the ratio of its power rating to its mass. Of the remaining power, some would be used to activate systems- installing movement systems, computers, and anything else would take a certain amount of this power. The leftover power provides the energy point pool for weapons and special systems. The ratio of motive to systems power could be adjusted by tuning. Tuning the engine too far to the motive side would make it unstable, just like the High Performance engine currently in the game.
It should be easier to create a small, light, highly maneuverable mecha than a big, heavy, highly maneuverable mecha. There could be diminishing returns involved- power might increase linearly, while engine mass increases quadratically. Size could figure into maneuverability somehow. Maybe the base MV score would be calculated by Body Size Class + number of limbs, or something.
It should be possible to change a mecha's engine.
Make armor more interesting
Currently, most mecha take a default armor value equal to their size class. Since this is the maximum armor value there isn't a whole lot of variation. Also, armor doesn't tend to be a big factor in MV/TR.
What about if the current armor rating/mass adjust system were completely abandoned? Instead, mecha limbs would get a material, thickness, and maybe a quality rating. Different materials would be used by different factions- Earth and Mars using types of steel, Luna using ceramics, the L5 colonies using advanced composites. The material would give the base mass for the armor. The thickness- thin, regular, heavy, superheavy- would give its protective value.
Maybe a greater distinction needs to be made between hitting a target and actually damaging it. A huge heavily armored mecha like the Savin should be fairly easy to hit, but unless you're really accurate it's tough to damage. This would increase the utility of weapons which just need to hit- BURN, OVERLOAD, and so on.
Different armor materials could have different characteristics- ceramic might be no tougher than steel, but perhaps harder to score a critical against.
Mecha Engineering could be used to change the thickness of armor, and if you have raw materials to also alter the composition.
Mecha Weaknesses?
This idea came from Mobile Suit Gundam. The Gouf is superior in nearly all ways to the Zaku II, but suffers from weak joints. Maybe some mecha should have weaknesses like this. It could lower the frame cost. Excessively modifying a frame might introduce weaknesses, depending on the Mecha Engineering roll. Once revealed you can use Mecha Engineering again to remove the weakness, which will either fix the problem or replace it with a different hidden weakness, which you can try to fix after it gets revealed.
The right tool for the job
Ideally, different mecha/layouts should be useful in different situations. You should want different equipment for attacking a spaceship than you'd want for skirmishing.
Big weapons and artillery should be most useful against props and less useful against mecha. Maybe a size class-based to-hit penalty if the weapon is over some arbitrary DC? Say, a DC24 weapon aimed at a Class 4 battroid might get a -5 to hit, but only -1 to hit against a Class 8.
You should be able to change your layout based on the fight you're expecting. Maybe a spaceship system should allow you to change your mecha's equipment to a number of user-defined combinations instantly? Of course, for this to be useful you'd need some way to know what to expect... that's a whole other kettle of fish.
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Comments? Any other bright ideas?