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Any time a settler comes to any of my settlements they come equipped with armour, which is normal. But in my save, when I try to remove that armour from their inventory, they just spawn new armour to replace it. It appears to spawn the armour from a levelled list as it varies with what they spawn.
I'm not sure what could be causing this as the only mod I have installed that effects settlers is the Useful Settlers mod, but that should only start them with armour and weapons that are levelled relative to the player character.

  • have you turned off the mod tried to remove their armor again? – fja3omega Jul 6 '18 at 2:58
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    Yes, I've disabled and uninstalled it and there's been no change with settlers that already exist or new ones that spawn. – MorbidEntree Jul 6 '18 at 3:21
  • Have you tried giving them different clothes after removing their armor? – fja3omega Jul 6 '18 at 3:56
  • Yes. I can remove one clothing or armour item, but as soon as I remove or add another, they spawn a replacement for what I took off them. – MorbidEntree Jul 6 '18 at 4:24
  • How quick is "as soon as"? Do they immediately get new armor, or is it you leave and come back and they have armor? If raiders attack while you're gone (or there are bodies laying around) settlers have the option of grabbing armor and weapons from the corpses. – MivaScott Jul 6 '18 at 20:09
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It's in all probability indeed a problem with that mod you use, Useful Settlers. After all, any behaviour deviating from vanilla behaviour is likely caused by mods you use, especially if one addresses settler inventory .

Moreover, in the comments section of that mod, someone seemingly complains about similar behaviour:

While this is a great mod for those wishing to never touch settler inventories, I like to customize and play around with different weapons and such. This mod puts unremoveable weapons and armor. I even disabled the mod, and now they have the items, but with a "0" after the item name. I can load up the settler, though. Oh, and don't try to remove the "0" items. You just get loaded down by phantom items that still have weight. Like I said, works like advertised, but you can't change things yourself.

So, unless you uninstall the mod (and this actually reverts all changes in-game, which it, based on that comment, won't completely do), you can only really bite that mini nuke, or see if a newer version fixe(s/d) that issue.

In vanilla Fallout 4, settlers have a basic set of clothes. Whenever you place equipment in their inventory, they will wear or wield whatever you choose (if they can). If any dynamic item of clothing is taken from their inventory, they will revert back to their default clothing.
I'm guessing the mod Useful Settlers made changes to that particular script, by having those standard clothes replaced by a list that levels with the player (like Encounter Zones, for example), with the probably unintended behaviour that it reverts to either the most recent item in that slot or another item from that levelled list.

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