I feel you, but I agree with
@BookBarbarian and
@LordEntrails , that making armor more realistic (DR) doesn't make sense unless you do something about hit points. That is what we did (but much simpler than what you have). Here is what we use:
Armor provides AC & DR. AC as normal and DR = AC-10.
DR only comes into play when your "bloodied"
Your are bloodied when your HP = 0 and then all remain hits take damage from your bloodied hit points (BHP)
When your bloodied the damage you take on a hit = the damage rolled - your armors DR
So when a fighter wearing plate armor is reduced to 0 hp, each hit after will be: damage rolled - 8.
You could make this system more complex or "realistic" by revising AC and DR values, or different values for different damage types, or adding lingering injuries, crits damage BHP & HP, etc. We tried some variations, but this simple approach scratched our realism itch and was the most fun for us.