I found a set of sweet power armor while tramping about the Commonwealth with Danse. Since I was in power armor myself, I gave the pieces to Danse to bring back(a laziness sort of move) and equipped it on him. When I did this, however...I must have made a huge mistake. His carry weight tanked. I tried to remove the pieces and put them on an empty frame, but his carry capacity is still just...it's gone, and I can't get his original power armor back. Because he's stuck in his own power armor frame, I can't get him into another set of power armor. I can't even give him power armor pieces to equip without the game saying he can't carry anymore, even if he's got diddly squat in his inventory. Has anyone else experienced this snaffu of sorts? He's currently just been left to trot around one of my settlements in his bare powerarmor frame since he can't carry anything.

Reload the save

His default armor gets added to his inventory and can't be removed, adding massive weight to him, don't change his armor, it only makes things worse.

Either A reload the save or B drop the power armor pieces on the ground tell him to pick it up and then equip. His carry weight will still be gone but at least he won't be walking around in an empty frame.

just kill it

That's what I was afraid of. His original armor doesn't show up in inventory but apparently still counts? T__T That stinks. I've gone too long without him to undo all of my progress for it. I was just hoping to see if there was a fix. I just won't mess with that stuff on him the next go around. I have no problem with Lone Wanderer and whatnot, but I actually don't mind having companions tag along sometimes. I think I am one of the few that don't absolute abhor followers. I like the company.

There was a similar thing in Skyrim: every time you dismissed one of your Housecarls, their apparent carry weight dropped, as if something inaccessible was stuck in their inventory.

Sure Danse can carry stuff - including PA pieces - no problem.
But for goodness sake, DON'T equip said PA pieces on his rig!
(Why would anyone ever do that...?)

I didn't know equipping them would create this problem and tank him.

Maybe to help him look cool for once in his miserable, uptight life?

It was the sweet armor and I was kinda antsy to see what it'd look like in action with the illuminated eyes instead of the side headlamp. Mistaaaake. T_T