So you get a henchman. But you can't just let him out there all alone. It's a big dark scary world, and he barely even has a name, much less any characterization! He needs a buddy.
Bonus points if the buddy is the physical opposite of the other, skinny where he is fat, or short where he is tall. Extra bonus points if you can use them as stand-ins to personify a much larger fighting force.
Often they are the funniest part of the story, and certainly have more personality than the evil overlord they work for. Revisit some of your favorites in this expandable list from Geekosystem. Link