Throwing around some ideas here:
Often there is a more heroic option for building characters. Hit points for example are often an average of SIZ (size) and CON (constitution). You could make the characters tougher by making hit points CON +1pt per SIZ point over 12 and WIL (willpower) over 13.
The damage bonus is another area where I'd consider making changes. It goes from 0 damage bonus up to adding 1D4, then to 1D6, then to 2D6, then 3D6, and so on. Seems like a big leap when it might be 1 pt of strength separating no damage bonus from an extra 1D4, let along another 1D6 bonus.
A more gradual progression of (in effect) adding 1D2 would be interesting to see, and you include that damage into one dice roll where possible. For example; A sword at 1D8 damage goes up to a 1D10 if the character is strong and/or big enough for one step damage bonus. The next step would be 1D12 (or 2D6 if you want which is even better), then 1D8+1D6, then 2D8, etc.
On the subject of weapons? I'm more about broad strokes there. Light Melee 1D6 (daggers, small clubs) Medium Melee 1D8 (broadsword, axe, spear) and then Heavy Melee 1D10 (great sword, two handed axe or spear). You could group energy pistols/rifles into similar groups, maybe with a bonus of +1/+2 damage for good measure.
Random armor value is an extra combat step, but fun when you don't use hit locations but want some variety versus the certainty that chain mail will absorb 4pts of damage each and every time. A 1D6 roll would add a lot of drama.