That's sad and annoying to hear about Sigourney Weaver. At least she apologised though.
On another note, I don't think the character of Aaron is at all brought down by his lack of intelligence and I never saw him as comic relief. He's less aggressive but he gets tense and scared so I'm not sure where the comedy really is there with that character. I like that he's less intelligent as that's a key part of his character and it makes a point that he's one of the last ones to survive and only doesn't because he bravely sacrificed himself.
you made me endure a bunch of theater no-names?
Were the actors not "no-names" I don't think it would have worked nearly as well as you'd lose immersion.
No reason they couldn't have gone back to the formula of 'Alien' and set it aboard a space station for much the same reason. 'Alien 3' doesn't really gain anything by being set on a planet.
I think 'Alien 3' being set on a planet makes it more interesting... well not necessarily a planet but the planet. Firstly, I think it could have come across as a lesser version of the original were it set on a spaceship; and secondly, putting your thoughts on the overall quality aside, do you not think the set design of the film is great? Something I like about the 'Alien' franchise is that each film has a different tone and feel while still feeling like part of the same story (which is one problem of 'Prometheus' - it doesn't have that feel). I think 'Alien 3' looks great and I really like the prison concept it went with.
The most suspenseful scene in Aliens was the facehugger scene because Ripley didn't have a gun.
Not to disagree but that scene does have the advantage of being longer. The motion tracker distance countdown scene is suspenseful. As is actually, the chase scene towards the end (the Queen chasing Ripley). And actually, the scene where the marines first enter the hive.
^ See this is why I disagree with the comment some people make that 'Aliens' is just a shoot-em-up with explosions and stuff. Aliens are killed but there is a load of suspense in that film.