I'd leave a spare 30-50lbs at least for heavy weapons, spare fusion cores, etc. The upper range on weight should be light encumbrance with a full combat loadout. Semi-Ablative materials like ceramics could replicate the armor damage system in Fallout 4 as well, and give players some much-needed risk in extended firefights.
A good goal is to give the armor DR 42, as that will completely block the 7d damage of a full-powered rifle. I designed mine around base ST 10, although a true military suit could be based on ST 12 for added protection. The added Lifting ST from the exoskeletons determines the effective weight limit of the armor. I use the armor design rules from Pyramid 3/85 to build the suit, then combine that with the basic exoskeletons from Ultra-Tech. Bit of a necro, but I've actually been doing something similar for my game.
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