In my game, armor does not 'stack'. It applies only to damage reduction for the part of the body it covers. There are twelve Hit Locations on the human body and twelve on mechs too, and they are the same:
Head, Left Torso, Right Torso, Center Torso, Left Lower/Upper Arm, Right Lower/Upper Arm, Left Lower/upper Leg, and right Lower/upper Leg.
When you take a "hit" you roll hit locations to see what part of the body was struck. This roll is done on a 12-sided dice to give equal chance of hitting each target*. Once hit location is determined, you add damage reduction for any armor to your total Vitality, and subtract that value from the initial (physical) damage dealt.
*Unless you aim at the head, in which case you get "Punch" hit locations and roll a 6-sided dice to hit one of the 6 upper body targets instead of the legs, which would be: Head, center torso, left torso, left arm, right torso, right arm. In this case, if an arm is struck, you determine randomly again whether it's lower or upper arm.
Magic damage hits the entire body, and ignores physical resistance. Instead, you subtract total Vitality from initial damage and then subtract RESISTANCE from the remaining value to find net damage.
Aiming at the Head of a Mech could be useful, because in my game, the head of a Mech has half as much HP as the next weakest part of the Mech. I'm still working on exact amounts, but I'm thinking the head should have 50 mech scale HP, which comes to 500 character scale HP.
What do you think? Too complicated? or about right?
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AI Opinion
I love crunchy combat systems, but this one sounds a bit slow at the table ⚔️
Twelve locations with separate armor is cool for mechs, but for humans it may bog things down. Rolling to hit, rolling location, then recalculating Vitality plus armor each time can drain the pace, especially in big fights.
You might keep 12 spots for mechs, but simplify humans to fewer regions or grouped armor zones. That way you still get tactical flavor without turning every attack into homework 📊
I'm doing this to simulate semi-realistic injuries from weapons. If you fall between 100 and 81 total HP, you are "stunned", but if you fall below 80HP, you are "wounded". If you are hit in the head or center torso on a "Wounded" result, you are instantly killed... even if you have 79HP remaining. It's because a head or heart shot with a shotgun or pistol should kill the character.