Well, there was a glitch a long time ago where if you implanted rex with Lupas brain it would not have any effect when it was supposed to make him more durable. I just tested it out and I think they did fix it because he doesn't die as often now.
Cheers guys, never really looked into Rex too much.... Or the Legion....
Only started getting into the Legion now, on the Couriers shoes thread my character - Lucius....
I recommend doing at least one legion playthrough. I was skeptical at first but I sided with them and it's been a lot of fun so far. It lacks a lot of quest and outposts but the challenge makes up for that. Rex is pretty good to but unless you or one of your companions is a melee character he might die a lot.