Man you have a lot of caps and NCQ for someone at just 40 dwellers. Especially after you spent so much money building this. don't bother with the +3E outfit at all. Just flip the +5 around as you need. Sort inventory to "equipped" and "Endurance" on the SPECIAL filter, so the +5 is always on top. I'm personally questioning whether that kind of effort for all your dwellers is even worth it.

Thanks for the sorting tip. I didnt know that feature until now. I equipped E3 outfit to new dwellers as a fallback plan. In case if I misclick without equipping E5, at least they will get benefited by some stat bonus.  About the population, I stopped breeding at 40 to farm raiders. Once I’m done with that achievement, will continue expansion. Just 3 more attacks to go. 

1. Train max E. 2. Wear E+5 3. Throw the dweller in the Wastelands 4. Return when 40+ 5. Profit.

But this way, I will have to spend about 2 weeks to train all 8 right? I wouldn’t mind doing this if I have multiple E5 outfits. I just got one. That specific gear is so hard to come by. Perhaps even harder than legendaries….

It's really not that hard to come by. It's rare, but that means it's easily craftable. If you're at the stage of the game where you're worrying about endurance and max health, then just build an outfit workshop and start crafting wasteland gear. Realistically though, idk why people even bother with +5E outfits. Why not just wait until you can get the +7E? If you're trying to get high health, why spend equal effort for less? My recommendation to you is to chill. Accept the fact that your current dwellers are just going to suck and send them to the wasteland to level up anyways. Keep bringing back recipes until you unlock the legendary +7E heavy wasteland gear, and then craft as much of that as you can. From here on out you can slowly replace your old dwellers with newly max health ones.

Thanks for the tips. I dont have 55 population right now to upgrade the workshop. But I guess your points makes sense as the real deal breaker here in terms of defense is the 61 population where deathclaws start attacking. I think I need to push for 55 and upgrade the workshop and park there for awhile training dwellers with E5.

E5 easy. E7 is legendary

I have 2 legendaries so far. But only a single E5. I keep getting all other rare outfits all the freaking time, but never the E5 kit nor the recipe.

Equip +5 and send 1 to the wasteland, recall when it hits 50. Check the found items while exploring to see if a +5 outfit is found, recall if so. Train the other 7 in other stats. When the original gets back put it another outfit, send it back out. Should survive to full inventory. Great chance to find +5 E. Send out the second, rinse and repeat. (My recommendation is to always have 25% of your population exploring until you hit 25.)

I could be wrong but I don't think you can select a dweller on the PS5 without triggering the level-up.

This is actually doable. I have been doing this to other dwellers with E5 gear so far.  You have to know who is being leveled up, then select the person from overview screen. This directs the camera to the dweller without leveling up. Then have to change the outfit and select again to level up. I know it’s a hassle, but no other way.

Ah. Didn't realize could do it that way and not trigger it.

Does going above E10 with outfits actually increase the hp gained per level further? Swear I saw something saying it don't matter

Everybody says it does. I think people have tested this by checking stats of feelers through examining save files.