Quickleaf
Legend
I didn't mean to, I swear!Dude, you totally stole my brainwave! Well, okay, my goons aren't exactly the same but close enough to be freaky. And I totally use goons more often than minions.

Just checked out your monster creation guide, and I think you're closer on the mark with your goons damage threshold than my quick and dirty version. Personally I don't like the threshold for minions as I *want* them to drop like flies to auto damage and such; but I understand why you'd want to have them last longer.
I've been wonderin what the XP values for minions and goons should be. My experience is that I often use 50% more minions than I planned (eg. 6 instead of 4).