Technik4 said:
The trickiest part for balancing things is if I keep Chain Shirt at +3 AC. The comparison to Studded Leather is inevitable, and by and large studded leather is a better choice.
According to your alternate armor stats, studded leather is indeed better than chain shirt... but that should not be so. Chain shirt should provide a better AC bonus and cost a good deal more than studded leather. Chain shirt should also be heavier and more cumbersome than studded leather. Historically and realistically, a shirt of chainmail was a definite step up in protection from studded leather.
I believe the following stats are more historical and realistic, yet still D&D-ish...
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LIGHT ARMOR
Quilted Cloth: 5 gps, Max Dex +7, Armor Check -1, Spot/Listen -0, 10 lbs., AC +1.
Soft Leather: 10 gps, Max Dex +8, Armor Check -0, Spot/Listen -0, 10 lbs., AC +1.
Hard Leather (Cuir Boulli): 20 gps, Max Dex +7, Armor Check -1, Spot/Listen -0, 15 lbs, AC +2.
Ringed Quilted: 25 gps, Max Dex +5, Armor Check -2, Spot/Listen -0, 20 lbs, AC +3.
Studded Leather: 50 gps, Max Dex +6, Armor Check -1, Spot/Listen -0, 20 lbs, AC +3.
Chain Shirt: 100 gps, Max Dex +5, Armor Check -2, Spot/Listen -0, 30 lbs, AC +4.
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MEDIUM ARMOR
Scale Mail (Scale Hauberk): 125 gps, Max Dex +4, Armor Check -3, Spot/Listen -2, 35 lbs, AC +5.
Chainmail: 150 gps, Max Dex +3, Armor Check -4, 45 lbs, Spot/Listen -3, AC +6.
Breastplate (w/ Bracers and Greeves): 350 gps, Max Dex +4, Armor Check -3, Spot/Listen -2, 40 lbs, AC +6.
Brigandine: 500 gps, Max Dex +3, Armor Check -4, 45 lbs, Spot/Listen -3, AC +7.
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HEAVY ARMOR
Splint Mail (Lamellar): 300 gps, Max Dex +2, Armor Check -5, Spot/Listen -3, 55 lbs, AC +7.
Banded Mail: 400 gps, Max Dex +1, Armor Check -6, Spot/Listen -3, 65 lbs, AC +8.
Halfplate (Plate Mail): 600 gps, Max Dex +0, Armor Check -7, Spot/Listen -4, 80 lbs, AC +9.
Full Plate: 1800 gps, Max Dex +1, Armor Check -6, 70 lbs, Spot/Listen -4, AC +10.
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BTW: I based these stats using the following reference materials...
M. Balent's "Paladium Book of Weapons & Armor"
G.C. Stone's "Arms and Amor"
GURPS Medieval
You'll notice the above armors are much heavier than the equivalents in 3E D&D, by-the-book. This is much more realistic, and will require characters with good Strengths in order to wear the heavier armors (when combined with their other gear), without going into heavy encumbrance.
The "Spot/Listen" penalties are due to various types of helms, each of which is integral part of the suit of armor.