Rexor and Thorgrim from Conan the Barbarian. They just stood around grinning and looking tough, and occasionally wiping out villages. Each one had a single line in the movie: Rexor’s was “KILL THEM!!!” and Thorgrim’s was an agonized “BLYEEEEAAAAARRRGH!” when he gets impaled on a booby-trap Conan had set for him.
And then there’s Pee-Wee Herman’s vampire character in Buffy the Vampire Slayer with the Death Scene That Wouldn’t End. “Oooh! Eee! Ouch! Aaagh! Ow!”
Now, let’s talk about least favorite henchmen: The Mutants, from Thundercats. I mean, come on, how were these buffoons a threat to anyone but themselves? No wonder Mumm-Ra never got anywhere.
How about Irregular Assignment? Actually, the coolest Austin Powers henchman (there were quite a few of them) was Number Two (Loved his straightman lines like “That has already happened” LOL).
Speaking of the henchman… In Chinese erotic classics, one nickname for the penis is “henchman.” (Cite: Sexual Secrets by Nik Douglas and Penny Singer, p. 313.) This has got to be my favorite “henchman” of all.
I’ll second TV’s Frank and Starscream. TVF’s chemistry with Forrester was amazing and the power struggle between Starscream and Megatron was truly underappreciated in the TF saga. Also, Starscream was pretty much Cobra Commander (arrogant and overconfident), right down to the voice (the late, great Chris Latta voiced them both).
Good guys can have henchmen, too. I nominate Major Thomas “Long Tom” Roberts, one of Doc Savage’s assistants. He was a bad-tempered electrical genius who looked unhealthy as hell, but could whip nine out of 10 guys he met.
The Doc Savage novels had plenty of interesting villainous henchmen. Two of my favorites are General Ino’s attorney Proudman Shaster who has a thing for decapitation and Toni Lash, a beautiful spy forced to help archvillain John Sunlight.