If you were to limit yourself to "no magic/psionics" and also "no 'blade magic'" (or whatever; lol), how would you go about bringing up to speed any mundane classes that might (in your opinion) need a boost, in as few steps as possible?
This may or may not jive with what you're wanting to do, but have you considered the d20 Conan RPG?
It sounds like it might hit the nail on the head for what you are asking for.
First off, there are tons of combat maneuvers, making combat quite fun without a single spell flying through the air.
I've made the game a tad livelier using the Optional Active Defense Rule.
LOOK HERE!
If you want to add in some magic later, you can. I don't have any magic in my game right now, and all the characters in the party are all Barbarians (1st level Cimmerian Barbarians). Here's some notes on my campaign:
CIMMERIAN BLOOD.
Of course, you can mix classes in the traditional D&D way, but you don't have to in this game. It's not as necessary as it is in normal D&D.
There are four hardened warrior classes: Barbarian, Borderer, Soldier, and Nomad.
Three softer classes: Noble, Thief, and Pirate.
And, two civilian classes: Temptress and Scholar.
Yep, that's right. You don't see "cleric" and "mage" and the like there. That's because any class can be molded into that. A pirate steps off his ship and is worshipped by the natives can take on the role of a cleric (shaman maybe) as much as the Scholar who studies the gods or the thief who assinates the head of a cult only to take that cult leader's place.
These classes all lend themselves to easy customization through multiclassing, too. A Soldier/Borderer might be a Scout. A Thief/Borderer might be a Bounty Hunter. A Pirate/Borderer might be an explorer. A Noble/Borderer might be an emissary....just to show you some Borderer combinations.
As far as some other highlights about the game:
-- Armor absorbs damage and doesn't make a character harder to hit.
-- The game is gritty and deadly. Weapons do more damage than what you see in D&D. For example, a two-handed greatsword does 2-18 damage (1d10 + 1d8). A shortsword does 1d8. A broadsword does 1d10.
-- All shields are rated for damage as well as thier protective bonuses, in case you use them to shield bash your opponent.
-- When you defend yourself, you have a choice of blocking a blow with your shield or weapon using the Parry maneuver, or spryly ducking out of the way with a Dodge maneuver. It is viable with this combat system to wear only a loincloth and survive in combat using the Dodge and Parry for your defense.
-- Sorcerery is dark and unnatural. Evil. Virgin blood makes your spells stronger. The entire magic system has been completely changed from what you see in the standard 3.5 D&D rules.
-- Also contributing to the grit and high weapon damage is a low Massive Damage threshold. 20 points of damage from one blow makes your opponent save or be dying in the negative hit points (You just lopped off his head!).
So, if this fits what you think you want to do, then you should check it out!