I'd just figure you'd use the Great Turtle solution for more Armor dots, like already on the MUL:
[img]http://www.masterunitlist.info/Unit/Card/1281?skill=4[img]
As for the ROLE section, it does need enough room for handwriting, as a given 'Mech can serve similar roles - a VLK could be a missile boat, a scout, or a striker, depending on a formation's needs.
One of the things I've been pondering is expanding the Special bubble until it matches the height of the Crit bubble; that way you'd have room to write ALL the Special Abilities the 'Mech has, whether it's from the 'Mech, quirks, pilots, or formations. That way the Defense bubble can expand right to match the length of the other bubbles, with room for a top bubble that includes Formation, Final PV, and Role. The Offense bubble might have to shrink a bit, but it's a bit overlarge for the information right now as it is.
In theory.
I'll have to restart into windows to do photoshop - damn you, GIMP! I don't understand you!