Here is one recommendation.. remove "no unusual effect" from the hit severity charts If I have gotten that far through the process that is more frustrating than interesting. (that is what the original save after the roll 20 gives you so why repeat it?). Make the save easier if you want all the unusual effects to be rarer.
I am planning on using something like these wound rules...
http://www.enworld.org/forum/4e-fan-creations-house-rules/240891-wound-system.html#post4649572
The idea is that things are grittier based on actual player desire, instead of the outcome of a die roll, it keeps things heroic.
The types of wounds needs much elaboration and since that seems your area of emphasis?