"The HG2 rule for armour 0 is clearer than the the rule for bays, and yet most people ignore the fact that to have armour 0 costs you tonnage. ."
I pulled out my copy of HG2 and checked this. It says you produce a basic hull (which has armor 0) and the armor section says you add armor to the basic hull at a set rate. I don't see where armor 0 costs tonnage since you can't add nothing to the basic hull.
Just to provide the contrary view...
The Hull is described as a "foundation onto which other parts are added" costing 0dtons and implying a framework, decks, internal bulkheads/compartments and a light outer skin. There is no mention of inherant armour.
The Armour section states "The armour factor is the type of armour used." 0 is a factor, "null" is not a factor, -1 is not allowed as a factor. It goes on to state "if no armour is selected, the armour factor is 0". This makes 0 a base armour factor/type for non-armoured ships.
The rules go on immediately to apply the chosen factor, without excepting armour factor/type 0.
The final sentance of the paragraph refers to "added value of armour" implying strongly that the added armour is added to a base line, I'd pick Armour factor/type 0. Onto which added value may not exceed the ships TL.
The only exception to this is the disperesed structure, which is excluded from consideration in the opening sentances of the paragraph and re-introduced in the second paragraph, giving it a default Armour-0 without having to pay for it.
Refering to Striker, which Frank Chadwick was working on at around the same time as he reviewed HG2, he applied a striker armour factor of 40 (= tank armour levels...) to HG ships with Armour-0, requiring 33cm thickness of steel at TL6 & 18cm at TL7-9, etc. Obviously Frank at the time thought Armour-0 was definately not the equivalent of 'no amour'. I very much doubt he intended the HG rule to be interpreted as Armour-0 is free.
In conclusion, I agree, we should all be paying for Armour-0. That we are not has doomed our brave starfarers to interstellar radiation, micrometeorites and knocks from portside dockworkers driving grav-lifts.
But we have all spent the last 30 years using an unspoken 'house-rule'. Changing or correcting this now means undoing 30 years of work. On this basis alone I hesitate to see it corrected.
Cheers!
Matt