Basically put I believe that AV+TB as it stands is too effective at stopping damage dead.
The average guardsman's total AV+TB value (seven) harmlessly turns aside one in three hits from a standard stub or las pistol, renders him immune to beatings from boots and fists, bludgeoning chair legs and effectively stab-proofs him as soon as he puts on his flak armour.
My proposal is simple, effective and easy:
Any hit that penetrates armour always does one point of damage before applying damage reduction from Toughness Bonus.
E.g.
Bill gets shot in the chest for 1d10+3 = 9 damage.
Bill has a Flak vest AV3 and a TB of 4 (lucky bill)
Old way
9 - AV3 = 6 - TB4 = 2
000
(armour reduction)
0000
(TB reduction)
2
(damage)
New way
9 - AV3 = 6* - TB4 = 2
000
(armour reduction)
1 (damage)
0000
(TB reduction)
1 (damage)
(*armour penetrated: 1 damage inflicted)
Basically the idea is that TB "skims damage off from the top" rather than being a cumulative threshold with AV making characters invulnerable to punches and knives as soon as they put on a flak jacket. (I'm being flippant but you know what I mean.)
Thoughts? anyone else tried ths before? I think I read something like this somewhere once.