Fat aluminium tubes are stiffer than thin steel ones.
That's right.
Two of my fairly most ridden steel bikes have classic 1" top tube, 1 1/8" down tube and 1" headsets. On roads and up to gravel category 2 (according to this classification:
https://cdn.shopify.com/s/files/1/0309/9521/files/Silca_Surface_Condition_Guide.pdf) without speeds over 45km/h the frames are stiff enough for me. Therefore I wouldn't care too much about that. Of course: if two bikes are nearly identical in fit, quality and parts I probably would opt for the stiffer one.
Heavy riders need to deal with peak loading, when you hit a bump or something without warning. You need fatter tyres or suspension to reduce the peak load.
Wider tyres are a good recommendation.
Imho the riding style is an important factor. With "active sitting" and anticipation relatively narrow tyres (in my case: real 26mm) with higher pressure are workable on roads and few meters on category 1 gravel but require a fairly careful riding style.
Cheap suspension is not very good or durable.
Where do I have to sign?
Good wide tyres with the optimal pressure will do a much better job and are cheaper to replace.
Lots of spokes help, at least 36, and a bike shop mechanic who can check the tension.
I fully agree with the first and the last.
In my experience 32 spokes
can be sufficient if the wheels are well built with quality components by a good wheel builder and if they are ridden with a careful riding style. In my case I know the wheel builder and the rider and can correct
mytheir mistakes. The 36 spokes add a bit of safety buffer.
Avoid anything that isn't standard.
This is very important.
Non standard parts usually are more expensive and spare parts are harder and harder to find over the years. Thanks to the widely used standards in older bikes it is possible to get compatible new parts in price ranges below "expensive" and "very expensive" nowadays: chain rings, brake pads, tyres, rims, brake and shifting cables, etc.
Disk brakes work well, even cable ones, and keep working well in the wet.
Good rim brakes mostly work well as well in the dry. Disk brakes mostly can do better than rim brakes in the wet.
That does not mean that good rim brakes are completely unusable in the wet but braking requires a tad more anticipation.
On early 90s MTBs/ATBs in most cases there are cantilever brakes. If they are in good condition, properly adjusted and have clean brake pads which work well with the specific rim then they probably are good enough. V brakes came in the late 90s, require in most cases different brake levers and are easier to adjust than cantilever brakes. There are a hand full of so called "Mini V Brakes" which are compatible with cantilever levers and dropbar levers, eg. from Tektro or Campagnolo.
I would pick a good bike shop and see what brands they offer. Some of the minor brands can be just as good as Trek/Specialized/Big Names.
Especially the latter: I fully agree.
With the budget of maximum $500 I'd opt for the second hand market.
I don't know if it's been mentioned but check the rear hub is a cassette rather than a freewheel which aren't as strong.
Good point. Fortunately in the early 90s cassette hubs took over very quickly. If it's not a bike for a historic collection, then I'd avoid everything that is not Shimano HG (that standard thing
@MichaelW2 mentioned, despite Shimano HG isn't a standard, but spare parts for other "old" cassette bodies are much harder to find and usually (much) more expensive).
Disclaimer: In the middle of 2024 my weight was 121kg. That's why I think that I can understand the challenges for heavier riders.
E.