Yeah, Conan is a rogue. Sorry to burst your bubble. He just took a level of Warblade for the weapon proficiencies.
If you want powerful and resilient, start by removing rage. The ability is definitely something for more a of a berserker.
Now, give them the ability to put an extra kick behind their swings, like a super-power attack perhaps, usable always.
Perhaps give him an armor-piercing ability so that he can still hit with it.
Give them damage reduction that actually matters.
Give them wilderness skills and the Endurance feat.
Let them reduce damage taken from non-mundane sources, too, like that Crusader damage pool.
Fast movement not necessary, medium armor not necessary, trap sense not necessary. This guy survives by one simple but powerful defense: you just can't kill him fast enough. Sure, he might have to waltz through a crowd, but he can take a hundred arrows and all the king's men before he finally chops the king's own head off with one mighty blow. Nothing fancy, nothing complex.
Base everything on level, so it's not so diptastic, and voila.
Just a barbarian; simple to play, simple to build, simple to use. As simple as his origins.
He marches into combat wearing fur and still emerges, bloodied, but alive and victorious.