Getting people to wear armor is easy. Trade with them (not barter, trade) then the T key to make them use either the weapon or the armor. In order to keep it simple I have companions use full cage-armor sets. Then I don’t have to assign each leg and arm and so on.
I’ll give it a look/shot. I’ve been doing fine without arming them/armoring them. Over 20 in most settlements, happy hovers 60-80.
Of course I ringed every settlement with about 80-140 points worth of heavy Turrets. it’s a Brotherhood thing...You wouldn’t understand...
/Steel Hipster