My apologies in advance if this build has been posted before; I have tried searching for a similar build, but didn't find. And sorry, but I'm NOT reading through all four versions of this thread to see if it's there...
... but anyway: This is my Overboard Tank. The idea isn't to deal damage. He can't. But he can avoid taking it - and if he takes it, he can stand a lot of it.
Race: Dwarf Alignment: Any lawful
Starting stats: STR 10 DEX 14 CON 20 WIS 10 INT 12 CHA 6
Level stat progression: 10 CON
Level 40 stats: STR 10 DEX 14 CON 30 WIS 10 INT 12 CHA 6
Through M levels: Max Tu, Co and Sc. At F1 take Di 5 and Co 5. At level 10 you have Di 5, Sc 6, Co 13 and Tu 13 (and saved 21) 11: Di 14, Sc 7, Co 14 (+12 saved) Now max Di, Sc, Co. Use the 12 saved points for Tu, when you are able to raise it again. Stop raising Sc and Tu at rank 20. 37: Di 40, Co 40, Sc 20, Tu 19 38: Di 41, Co 41 (+1 saved) 39: Di 42, Co 42, Tu 20
And finally at level 40 you have: 40: Di 43, Co 43, Tu 20, Sc 20, He 1
This combo has up to 882 HP. He has good saves (Fort 38, Ref 28, Will 30) - even better against spells (+6) and traps (+1), Deflect Arrows against archers, Improved evasion for those nasty AoE spells, can't be flanked and invisible/hidden do not get bonus to hit him, Defensive stance for even more HP and better saves and better AC, he's immune to diease/poison, has physical DR of 30/-, and has 10 points of Resistance to all energy forms (except fire where he's got 15).
He may not kill you with his weapon, but you might die from boredom before -you- kill -him-