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Rules question here...

By the rules it states that his armor reduces the strength of any melta, plasma, volkite, fusion and flamer weapons by half (round down). This would effectively make him immune to certain weapons since his Toughness is 7.

How would that play out though if he had joined another unit? (A bodyguard unit of Termies for example). Since you roll to wound against majority Toughness.

A good question..
I guess as you roll against the majority, this ability would not work until it was just him and one other guy.

But the squad's majority toughness that he joins is not 7 so pretty situationional except on his own.