I know you've probably reached a decision there, but for the sake of argument, I'm not quite dropping it yet.
I can accept the argument that modeling the density of materials would go too far, in the same sense that you didn't want to incorporate regular materials for the sake of not getting it overly complicated.
However, you could easily abstract it.
Given the current code, you could just reduce the mass of the ship by a percentage, based on an arbitrary value, for example the weight to volume ratio of a space shuttle.
Given the raw data here, I've calculated a base value for it, using the following assumptions:
As length, I picked 32 meters, which is close enough given it's obviously not a cube, and omits part of the fins and all that jazz.
Given the rather inaccurate data provided by that site, I just assumed it to be 5x5 in height and width, which is probably a rather generous assumption.
With 32*5*5 (I have this mad feeling of totally missing something right now), I got a total of 800 cubic meters; given that I fully expect to miscalculate something here, let's just assume half of it.
However, the full load of the shuttle seems to be, according to wikipedia, around 109 tons.
So, to take the middleground between what is in game now and the cheap calculation I just pulled off, you could reduce the weight of a ship by roughly 35%.
This would change the given freighter from:to:
Atlas class Freighter 6,105 tons standard 32,105 tons full load 35,393 tons volume 28 Crew 431.1 BP
Length 220m Armour 1-176 Sensors 1/1/0/0 Damage Control Rating 1 PPV 0
Now, I obviously don't know too much about the subject, but I think this wouldn't be too much coding effort, and as with the exhaust problem before, you could just change the fuel consumption to account for that; In this case it would probably go down a bit again.
Though, now that I think about it, crew spaces should probably handle only half as many persons after that model, maybe 2 or 3 per ton.
As for railguns, does that mean we'll have to expect the muzzle velocities to go down by an order of magnitude? After all, a somewhat similar change was enacted on engines to keep with the realism.
Already built into Newtonian Aurora is that the volume of a ship in cubic metres = 10x mass in tons. This is will be too low for some ships and too high for others but it will suffice as an average. As a comparison, Traveller TNE uses volume m3 = 14x mass in tons. Of course, mass will change significantly during the game based on how much of the maximum fuel load is carried or whether a cargo ship is actually carrying any cargo, so the volume - mass ratio of a ship will change a lot during the normal course of play.
I could calculate individual volume - mass ratios for every component but my reasons for not doing so are as follows:
1) It would be a lot of work, especially in terms of the research required to create reasonable ratios for each component. If I was not going to research it enough to come up with reasonable ratios then what would be the point.
2) Even though different components would have different mass ratios, ships tend to use the same type of components. Engines, armour, weapons, crew quarters, fuel, etc. So even though the individual components may vary, warships would probably have similar average mass-volume ratios anyway.
3) When you see the TCS of a ship with a fixed mass-volume ratio for its full load mass, you will have a reasonable idea of the capability of the ship. Otherwise, I would just display the diameter of the contact in metres, which to most players wouldn't be that useful. They would like an idea of what they are facing. If they were an experienced naval officer, they may know how TCS generally related to possible mass ranges for different ships of different nations. However, they aren't and most players will want 'Sensor Reading' = 'General Idea of Ship Capability', and in Aurora terms 'Ship Capability' is closely related to mass. If they need to know mass they need to know how volume relates to mass without a lot of calculations.
4) Most importantly, having different mass ratios for different components wouldn't significantly affect gameplay. Players are unlikely to design their ships any differently based on the mass/volume ratio of the components. If you want an escort DD then you will pick the components you need and select engines based on how much mass you need to propel. You won't care about the volume during design. Volume changes will affect the chance of a hit but not by a great deal and certainly not enough for you to make different decisions during design, especially as it is likely that ships of a given role, such as warships, would probbaly have similar mass-volume ratios anyway.
5) With 4) in mind, I really don't want to expend a lot of effort on something that might add more realism but would have very little impact on gameplay. Gameplay in this context being the addition of difficult decisions related to the volume of a component.
Volume is included because I am using it as a baseline for to hit chances and the impact of nukes. It isn't intended to have a significant effect in gameplay.
Steve