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I started out with a BHI vest which is fairly thin but recently started using a molle plate carrier without plates. only reason I changed rigs is because I too carry way too much and needed a molle rig. 8-12 metal primary mags, another 3-8 pistol mags and pistols (1xleg rig, 2 on belt on back, 1 somewhere in a mag pouch or tucked in my chest), up to 5x40mm (3 of which are always kings), radio, snacks, 3L camelbak, and an m500 in a scabbard on my back. that's the most I might carry but a good rig will distribute the weight nicely.
a plate carrier is already thick enough that you can feel a BB hit but it won't hurt. now if we could just get people with plate carriers not to insert the foam/plastic plates........ lol
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