With a bit a of experimentation I can build a 17 dT fighter with 4 times reinforced hull at TL12. Statistically the turret will be disabled before the craft is destroyed, so no reason to add more reinforcement.
I'm surprised there's no limit to how much you can reinforce the hull/structure (aside from the volume, off course). Yes, this way you can make them more resistent, at a cost on other oerformances, I guess...
About when the weapons will be disabled, that would depend on the combat rules you use. If you're using barrage rules, you don't care about it, as fighters are outright destroyed (at most you will have one of them damaged).
No, (HG, p74):
An attack with a barrage roll is made by rolling two dice and with dice modifiers for range, fire control software, dodging, Gunner skill and ship defences.
But that is not an automatic action, it requires a pilot task roll. So you should roll for each craft, if we want to apply RAW, and then, how to treat the squadron as somones will succeed and othres will fail?
I've always assumed that this was included in the -4 against fighter squadrons, and only really applied to major ships (whree you can roll for each of them), but I must concede that's not specified in the rules
Not a problem with reinforced fighters? Unreinforced fighters are too fragile to use?
I keep thinking that the main defense for fighters is avoiding being hit, not resisting hits, but this should be tested...
With the -4 for shooting at squadrons (and reinforcements):
100 light fighter shoots:
Barrage DM: +4[crew] +4[FC] +3[WpnDice] +2[VHYield] -4[Sqn] -2[range] -2[Dodge] -12[armour] ≈ -7 => Average Dam 3,6%, so 100 × 3 × 3,6% ≈ 10,8 total, not even killing a single heavy fighter.
50 heavy fighter shoots back:
Barrage DM: +4[crew] +4[FC] +4[WpnDice] +2[VHYield] -4[Sqn] -2[range] -2[Dodge] -12[armour] ≈ -6 => Average Dam 8%, so 50 × 4 × 8% ≈ 16 total, killing 2 light fighters.
As said above, I assumed that the -2 for dodging was included in he -4 for squadrons, and the -2 for distance will fade when they close, but you're right, they are not easy to hit.
It seems much easier to attack each fighter directly, which we can according to p80.
Of course, if (for the skirmish I told above where 100 light fighters engage 50 heavy ones) you're willing to roll for the 150 dodging rolls, plus the 150 to hit rolls, plus the damage rolls for those that hit (and of course you'll need to know the exact skill of all crewmembers, no longer averaging them)...
Personaly, I see it as a sure way to bog down the game, so, for better or worse, I'd use the barrage rules for this kind of battles and fleet games.
For Player's ships' combat, of course, things would be different, but I'd also expect numbers not to be so large.
Below TL12 you do not have access to Point Defence Networks, hence you can overwhelm a single ship's point defence by concentrating fire.
How do you overload them?
Unless TCS changes it, even a single turret will give you the defense benefit (albeit probably at the -1 for being less than 90%), so, unless you have more ships to attack tan it has turrets dedicated to PD, it's quite difficult to do it...