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I'm building a Henchmen list revolving around the Jokaero and Warrior Acolytes and came across a bit of a fork:

In each Henchmen squad I'm running two Jokaero and roughly eight Warrior Acolytes w/ Storm Bolters. Since the Jokaero can improve the Armor and (possibly) give the unit ++5 Invuln, is it worth upgrading the Flak Armor to Carapace? Though they're double the price, Warrior Acolytes are roughly cheaper than a Tau Fire Warrior (by a two Points), but get a save against small arms fire in addition to anything the Jokaero does.

The Carapace seems like a decent investment to keep the unit alive as long as possible and use the buffs the Joakero dishes out.

To level out the points cost, I'd drop the Imperial Guard Allies I wrote in my 1850 list and go completely Grey Knights.

Honestly, upgrading to carapace is never a good investment, just buy more guys instead and park them in ruins/terrain to get free saves. Making cheap guys expensive is never a better purchase then buying mroe cheap guys. Especially since it's just as effective as buy more armor, but you get more shooting as well.

I agree with Coyote, it'd be better to invest in a transport or stronger weapons. Remember Coteaz can throw divination powers on them.

Double the cost, for slightly more than 50% increase in survivability just isn't worth it.

Carapace can be worth it for plasma/melta henchmen, as you're only paying 30% extra for 50% better survivability (against some weapons). But that is really only true if the squad has already been maxed out, otherwise you're pretty much always better off by bying more henchmen.

Though it depends what else you have. For example, having ADL changes things a lot...