I know I'm dredging this back up again, but there is one added "fix" to consider. It requires a house rule though.
Why does any of the armor have a Defense value? Why isn't armor just limited to Soak, except for the Personal Deflector Shield? I think it could be a hold-over from FFG Warhammer which needed another defensive value to incorporate to further differentiate more and varied types of armor then we have in a Star Wars universe.
Vehicles and spaceships have both Armor (hull plating) and Defense (shields) ratings. If the craft doesn't have shields, it doesn't have Defense. So, why does personal armor without shields receive a Defense score? If the counter-argument is some armor can "deflect" away an attack, that is just some verbage to justify the use without much logic to it. Can I put some slanted hull armor plating on my X-wing to allow it to deflect away attacks and so gain a defense value without using shields? Armor soaks, shields deflect, is much more simple and believable.
Removing the Defense from personal armor only changes Armored Clothing and Heavy Battle Armor. They both still have Soak values, so they are still useful. You can compenstate by changing Price, Encumbrance, or Hard Points to fill in what they have lost and/or make them different enough from other armors to be a consideration. The Personal Deflector Shield would not change, it would keep it's 2 Defense, as it is of course a shield.
From a simplistic stand point it just makes sense to me. A knight in shining armor holding a shield should have a Soak value from his plate armor and Defense (setback die) from his shield. One absorbs blows, one makes it harder to be hit in the first place.
A bonus would be nearly removing the argument over environmental cover stacking with personal armor defense.
Yet, one could counter-argue that your knight's shield is actually just soaking damage like the armor.
Yeah, you can parry a sword with a shield. But, you can just as easily parry a sword with a thick steel gauntlet. That **** isn't getting through.
What is armor but just a giant body-shield?
Thick armor CAN deflect. If the attack is slowed down so much that it doesn't even bite into the armor, then there's no need for it to soak up anything. If you shot a mandalorian, soak wouldn't matter if the shot didn't even pierce the armor. It would only matter if you scored a major hit (and hitting despite that defense die). Then, your soak would kick in my slowing down the shot before it hits you, and by taking the heat so your body doesn't have to.
Planetary scale=/=Personal scale. While Shields and Defense work mechanically similar, they are not the same thematically. And, when approaching this system, I am a proponent of disallowing mechanics to overshadow thematic and narrative flair.
Which is why I'm letting armor and cover stack, since it only makes sense that it would be harder to shoot through thick armor while also trying not to hit the cover they are ducking behind than it would be to hit the target anywhere while they are behind cover (because they're naked or wearing no armor.) It only makes sense.