Something I just remembered: I and a friend recently applied for a PbP game that basically revolved around fighting cats until we die (with eventually >200 cats coming at us at once being announced). DR and similar outright immunity to housecats was strictly outlawed, so we went for this build:
Dragonborn Water Orc Crusader//Totemist
Str 20
Dex 12
Con 22
Int 6
Wis 4 or 6
Cha 4 or 6
Flaw (Pathetic: Wis or Cha) - Bind Vestige
Flaw (Inattentive) - Improved Bind Vestige
1 - Shape Soulmeld (Mantle of Flame)
Traits: Slow, Night-Sighted
Totemist melds shaped:
Rageclaws
Wormtail Belt
Equipment:
Tower Shield
Flail
Club
Other assorted stuff
With 1d10 HD, 22 Con, Slow, and Rageclaws, this has 17 hit points and doesn't drop dead until it hits -10, effectively giving it 27 hit points. Wormtail Belt, Savnok's Full Plate (which is +1 due to your EBL being treated as 5), Dex, and the Tower shield add up to 26 AC. The point of essentia it gets goes into Mantle of Flame.
Most monsters of remotely appropiate CR will have a very hard time hitting. When they do hit, they're reqarded for their trouble with 2d6 fire damage, and the orc can heal with Martial Spirit and Crusader's Strike. Now, this is specialized to survive critters that only ever deal 1 damage on every attack and have 2 hp each, but it should hold up outside this scenario too. One could drop Mantle of Flame for Stone Power to capitalize on Steely Resolve, for example, and then put the essentia into Rageclaws for 3 extra hp or Wormtail Belt for even more AC.