Returning to the topic of the Zero's armor one of the interesting questions is why the A6M received armor so late.
To summarize what is written in the どうして?で読み解く零戦発達史 about this theme and adding some my thoughts:
According to initial plans IJN wanted to cease Zero production by 1944 switching to the production of new-generation fighters. However due to the failures of the J2M, A7M, and other aircraft these plans were thwarted. And looks like to the desire to stop production of A6M development of new modifications was slowed down.
Therefore urgent work began on improving the Zero and one of the results of which was the A6M5 Hei. It was not developed by Jiro Horikoshi, but by the team of Eitaro Sano, the designer of the F1M2.
In essence, the A6M5 Hei was not a "logical evolution of Zero" but an attempt to bring the performance of an outdated aircraft up to that of a new generation of fighters. Therefore its design incorporated armored glass (front and rear), armored back plate and self-sealing fuel tanks (only planned).
A6M5 Otsu (as the first Zero with armor) got its front armored glass because it was decided to implement some of the solutions from the A6M5 Hei to the A6M5 Otsu due to the almost parallel production.
Self-sealing fuel tanks were planned for the serial production of A6M6c (Model 53) but due to problems with the water-methanol injection system on Sakae 31 this version did not enter production.
Meanwhile A6M5 Hei did not receive self-sealed fuel tanks due to problems with the production of synthetic rubber for the inner rubber layer. (looks like creating fuel tanks with an outer layer required a complete redesign of the tanks and part of the wing which was apparently abandoned due to the urgent need for mass production)
Also there is a certain paradox regarding armor. Many photographs of the A6M5 Hei and A6M7 show the rear armored glass missing. It is impossible to see from these photographs whether the rear armored back plate is present. It is also possible missing.
Photo of A6M5 Hei with armored glass clearly seen and it is the only with it I could find at the moment
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Modern photo of A6M7 which clearly shows how cockpit with armored glass should look like
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And some examples with clearly missing armored glass
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But the front armored glass is present in all photographs.
It is unclear whether the lack of rear armor was due to the pilots' desire to lighten the aircraft (the rear armor were removable and manual clearly stated the stage for removing it) or because the aircraft were already being delivered without rear armor.
Zero was also equipped with automatic fuel tank fire suppression systems (tbh this system is surprisingly rarely discussed despite its widespread use among naval aircraft and even some army aircraft manufactured by Mitsubishi)
Fuel tank fire extinguishers were initially developed in the late 1930s after the fighting in China but entered mass production only in spring of 1943 on the G4M.
A6M5 Model 52 received this system only in December 1943 and it only worked on the wing fuel tanks. Overall according to various literature this system proved quite effective and many squadrons praised its performance and expressed official gratitude to engineers.
However there were complaints that the system did not extinguish the fuselage fuel tank so on A6M5 Otsu also added fuselage fuel tank fire extinguisher.
After activation (in memories of one G4M crew member said that it was activated before combat) this system automatically detected fire and released CO2 for extinguish fire.
A6M5 had two CO2 ballons: one extinguished both left wing tanks another - the right wing tanks (I don't know if a third ballon was added for the fuselage tank on the A6M5 Otsu).
Scheme of automatic fire extinguisher on early A6M5
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Photos of CO2 ballons (full green) and system control box in A6M5 from Robert C. Mikesh book (interesting that it is described as engine fire extinguisher bottles but since engine fire extinguishers was deleted from A6M5 and it placed same as on scheme above - it is fuel tanks extinguishers)
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The topic of the A6M5 Hei armament was also raised. Although it was standardly armed with three Type 3 13.2mm machine guns sometimes (pretty rare) fuselage Type 3 was removed (can be seen on one of the photo above). And I think it was removed not so much to reduce weight as to free up space in the fuselage.
Type 3 took up a lot of space in the fuselage and possibly it was placed on right side of fuselage to avoid interfering with pilots entering the cockpit from the left.
Rear of Type 3 is clearly visible in cockpit.
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