No transporter or replicators. Stick with the shuttle craft and if thats too much for the special effects budjet beaming will involve riding a force field down the tractor beam without all that silly being disasembeled and reasembeled malarky.
It's funny how so much of the ideas here essentially amount to fancy military stuff that probably wouldn't even go by the budget and would go against the whole spirit of the show. Starfleet guys in some super-wank-Marine-armor? Please.
Also, in regards to story arcs, that actually isn't a very doable idea. Episodes were often broadcast in rather random orders at the time, which is why the series ended with the one it did. I suppose the best one could do would have some sort of big event in one season, like Best of Both Worlds, and reference it the next in another episode.
So the spirit of the show is to create a wildly unrealistic socialist's wet dream of a society, which just happens to be completely incapable of fighting a single battle without blind luck or semi-divine intervention, let alone a whole war, while existing in a fairly hostile part of the galaxy? Clearly, if you'd ever watched TOS, that wasn't quite the point. It was when they had to try to respond to the fall of the Soviets in TNG that things went to shit. Thus, aside from the few people who want to completely rewrite the storyline and backstory, most of us just want to head off the morons who wrote TNG's stories.
No, the spirit of the show was about peaceful exploration and exploring new frontiers, wild west style (in theory anyway), not Starship Troopers with redshirts, which is want some people seem to be after. Besides, given the context of the OP, TNG shouldn't really be factoring into this at all.
Well, knowing what we know now, it's pretty hard not to want to head off TNG at the pass. TOS was entertaining while being realistic and not dumb beyond all imagining, in a way that TNG, DS9, and Voyager were not. Frankly, I think that Enterprise surpassed the latter three by far.
That I want the Federation to be a realistic interstellar polity is not unreasonable, in my mind. And a rational military and economic policy would come under those headings, as would the occasional exploration of its defensive or industrial abilities.
Well, DS9 tried to address some of that sort of criticism over TNG, no? Anyway, TOS seemed that way because ultimately it didn't really go into that much detail about how the Federation worked, and left it more to the imagination. Really, it would be better to drop clear hints in episodes, as 60s viewers really won't give a damn about its domestic defence policies and whatnot. E.g. mentioning 'you can't get past all of Earth's orbital defence nets, that's impossible!' or something.
They get involved in a decently large shooting battle around Sol system, just enough to establish that Sol has a strong defense net, a lot of industrial power in system (hooray for the ability to produce bomb-pumped laser mines in huge numbers!) and a decent-sized "Home Fleet."
Sounds fair enough, although you have to keep in mind SFX limitations. I also think TMP, snooze-inducing as it was, had Earth shielded and with defence sats.
To potter backward to body armour, I have a recommendation. Replace it with a belt with a personal shielding device on it. Smaller, thus easier to store, funky and high tech, and stops everyone looking as though they're in a game of Halo.