Ok, my take so far. We really need a consolidation of the build rules and tech items. They are scattered everywhere and often contradictory or at least incompatible with other rules and tech.
Life support and crew requirements needs clarification and better examples. Often on official designs, the crew requirements listed do not match those in the design rules. And the effects of having one crew hold multiple jobs isn't discussed anywhere. (I don't have all the rulebooks, but I have the Core, HG, ACS, SCC and SOM, which I'm still working through.) Also, the effects on crew of not having sufficient Common Area is never mentioned beyond saying it has some sort of effect. Also, I've been told that a small craft with a cockpit only has 24 hours of oxygen and no way to improve it. Why not? What about adding an Acceleration Seat and Common Area, would that change the calculation? Or putting in a 1 dTon Biosphere?
After talking with Terry Mixon, it's blindingly clear that automation is the way to go for Starships, but the rules are vague and not clear. I'm still working my way through the Robot Handbook, but how do those integrate with the ship building and crew rules?
Also, as a personal project, I started going through all the books working on correcting all the errors in the ships and small craft. I've done Core, High Guard and most of the Small Craft Catalogue. About 1/3 of the designs have some error, some of them very egregious. Most common is cost, usually due to a typo or using the incorrect value for a component. 2nd most common is incorrect tonnage values, usually from typos or not using the correct value from HG for the components. The 3rd most common issue is not following the build rules. This is very prevalent in Modules, where the rules are clear that they cannot have computers, power plants, maneuver drives or operate independently. And yet we have all of these appearing in official designs, some designs with all of them. I don't think there is any reason to exclude these things, but that needs to be updated in the rules. I think allowing modules to be fully capable ships on there own would be fine as long as they are built as ships. If built as modules, they get the bonus of cheaper hulls but then must be limited to only being used aboard ship or possibly on a planet with appropriate atmosphere. The ability to add gravitics to the hull of the modules would be good for those times when it's being used but not connected to the ship.
Also, much thanks to Arkathan and his spreadsheet. That's the only I've been able to reconcile as much of the rules as I have been able to.