So, I want to be tough.
Invuln
WP
Elec
Dark
Dark Armor isn't so terrible endurance-wise as it's clicky.
I think only WP fits your bill.
I'd hardly call DA "clicky" with Dark Regeneration being it's only click power.
SinisterDirge's list is probably about the same as what I'd recommend.
If you don't like clickiness then Willpower is your best bet. There are... no clicks save for the rez and t9. Invuln is awesome too but you gotta either build for psi defense or try and avoid it.
I'll second Elec... even though it is kinda clicky. You get decent resistance to everything and amazing resistance to energy plus you can always build for s/l or positional defense. You'll have no endurance troubles with Power Sink, but that requires clicking. Energize is amazing, too... but its clickiness depends on how you use it. You could put it on auto for the buffs if you aim to make it perma, or use it as a heal. Your choice.
DM/Invul. Doesn't get much tougher than that.
Soft-capped to everything but Psi and extremely high resistance to S/L with good resist to everything else. About a 340HP heal (higher on a Brute) every 2.46 seconds. This is a Scrapper build so you can easily switch it to a Brute and even clean it up a bit. If you can fit in Overcharge and Unstoppable you can use that twice in a row. Expensive as hell but it's something worth looking at.
Hero Plan by Mids' Hero Designer 1.952
http://www.cohplanner.com/
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Level 50 Magic Scrapper
Primary Power Set: Dark Melee
Secondary Power Set: Invulnerability
Power Pool: Leaping
Power Pool: Fighting
Power Pool: Leadership
Power Pool: Speed
Ancillary Pool: Blaze Mastery
Hero Profile:
Level 1: Smite -- KntkC'bat-Acc/Dmg(A), KntkC'bat-Dmg/EndRdx(3), KntkC'bat-Dmg/Rchg(5), KntkC'bat-Dmg/EndRdx/Rchg(13)
Level 1: Resist Physical Damage -- RctvArm-ResDam(A), RctvArm-ResDam/EndRdx(17), RctvArm-ResDam/Rchg(19), RctvArm-ResDam/EndRdx/Rchg(31)
Level 2: Shadow Maul -- Armgdn-Dam%(A), Armgdn-Dmg/Rchg(3), Armgdn-Acc/Dmg/Rchg(5), Armgdn-Acc/Rchg(17), Armgdn-Dmg/EndRdx(34)
Level 4: Temp Invulnerability -- RctvArm-ResDam(A), RctvArm-ResDam/EndRdx(11), RctvArm-ResDam/Rchg(11), RctvArm-ResDam/EndRdx/Rchg(25)
Level 6: Dull Pain -- Dct'dW-Rchg(A), Dct'dW-EndRdx/Rchg(7), Dct'dW-Heal/Rchg(7), Dct'dW-Heal/EndRdx/Rchg(37), Dct'dW-Heal(37)
Level 8: Siphon Life -- KntkC'bat-Acc/Dmg(A), KntkC'bat-Dmg/EndRdx(9), KntkC'bat-Dmg/Rchg(9), KntkC'bat-Dmg/EndRdx/Rchg(13), C'ngImp-Acc/Dmg/Rchg(19), T'Death-Acc/Dmg(43)
Level 10: Combat Jumping -- LkGmblr-Rchg+(A)
Level 12: Boxing -- Empty(A)
Level 14: Tough -- RctvArm-ResDam(A), RctvArm-ResDam/EndRdx(15), RctvArm-ResDam/Rchg(15), RctvArm-ResDam/EndRdx/Rchg(25)
Level 16: Unyielding -- Aegis-ResDam/EndRdx(A), Aegis-Psi/Status(42), Aegis-ResDam(42), Aegis-ResDam/EndRdx/Rchg(45), Aegis-ResDam/Rchg(45)
Level 18: Resist Elements -- S'fstPrt-ResDam/Def+(A), GA-3defTpProc(34)
Level 20: Weave -- LkGmblr-Def(A), LkGmblr-Def/EndRdx(21), LkGmblr-Rchg+(21)
Level 22: Maneuvers -- LkGmblr-Def(A), LkGmblr-Def/EndRdx(23), LkGmblr-Rchg+(23)
Level 24: Super Jump -- Jump-I(A)
Level 26: Soul Drain -- C'ngBlow-Acc/Rchg(A), C'ngBlow-Acc/Dmg(27), C'ngBlow-Dmg/Rchg(27), Erad-Acc/Rchg(36), Erad-Acc/Dmg/Rchg(39), Erad-Dmg/Rchg(40)
Level 28: Invincibility -- LkGmblr-Def(A), LkGmblr-Def/EndRdx(29), LkGmblr-Rchg+(29)
Level 30: Dark Consumption -- C'ngBlow-Acc/Rchg(A), C'ngBlow-Acc/Dmg(31), C'ngBlow-Dmg/Rchg(31), Erad-Acc/Rchg(37), Erad-Acc/Dmg/Rchg(39), Erad-Dmg/Rchg(40)
Level 32: Midnight Grasp -- KntkC'bat-Dmg/EndRdx/Rchg(A), KntkC'bat-Acc/Dmg(33), KntkC'bat-Dmg/EndRdx(33), KntkC'bat-Dmg/Rchg(33), C'ngImp-Acc/Dmg/Rchg(34)
Level 35: Tough Hide -- LkGmblr-Def(A), LkGmblr-Def/EndRdx(36), LkGmblr-Rchg+(36)
Level 38: Resist Energies -- Aegis-ResDam(A), Aegis-ResDam/EndRdx(43), Aegis-EndRdx/Rchg(43)
Level 41: Ring of Fire -- Thundr-Acc/Dmg/Rchg(A)
Level 44: Fire Blast -- Thundr-Acc/Dmg/Rchg(A), Thundr-Acc/Dmg(45), Thundr-Dmg/EndRdx(46), Thundr-Dmg/Rchg(46)
Level 47: Fire Ball -- Ragnrk-Knock%(A), Ragnrk-Dmg/Rchg(48), Ragnrk-Acc/Dmg/Rchg(48), Ragnrk-Acc/Rchg(48), Ragnrk-Dmg/EndRdx(50)
Level 49: Hasten -- RechRdx-I(A), RechRdx-I(50), RechRdx-I(50)
Level 50: Spiritual Core Paragon
Level 0: Portal Jockey
Level 0: Task Force Commander
Level 0: The Atlas Medallion
Level 0: Freedom Phalanx Reserve
Level 50: Reactive Radial Flawless Interface
Level 50: Ageless Core Epiphany
Level 50: Pyronic Radial Final Judgement
------------
Level 1: Brawl -- Empty(A)
Level 1: Critical Hit
Level 1: Sprint -- Empty(A)
Level 2: Rest -- Empty(A)
Level 4: Ninja Run
Level 2: Swift -- Empty(A)
Level 2: Health -- Mrcl-Rcvry+(A), Numna-Regen/Rcvry+(42)
Level 2: Hurdle -- Empty(A)
Level 2: Stamina -- P'Shift-EndMod(A), P'Shift-EndMod/Acc(39), P'Shift-EndMod/Rchg(40), P'Shift-End%(46)
Dark is the ultimate for survivability, willpower the the penultimate but has no clicks. A shield character can get good defense to all but non-positional psy attacks, so very few weaknesses (I've pretty much done all the solo-content in the game at +1/*8/AVs on mine, but super expensive build), but you've already said you don't want /SD.
If you want I'll post a build I've been working on for a cheap Katana/Dark Brute that is soft-capped to every position (no purples, no PvPs). I'm still editing it (trying to restructure it around Barrier), but it should work well for a template. I also could do one for Willpower if you want. Dark should be fine if you can get about 2 end/sec after toggles and slot Dark Regeneration well (theft of essence proc and end reduction mainly). Werner is the guru for that combination, so talk with him.
Willpower goes good with anything. All you need is decent defenses (capped smashing/lethal is great), and you'll be set for anything.
TW/Elec Optimization
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TW/Elec Optimization
/willpower
I am looking for a secondary which makes me go trough the game content with not many weaknesses. I'd like to be as tough as possible, in first instance, and:
- have a reasonable end management
- have a reliable way of healing myself
- not clickie intensive
oh and no SD, need to pair with couple sets which do not allow it.
My first thoughts were towards dark armor, I like the versatility but end management looks terrible.