Hi guys, wow what a response!
Let me just clarify a few things:
The neutral good fighter decided to draw his sword to attack Horgus, he did not declare non-lethal damage until after the attack, when another player suggested it in the hope of the -4 penalty incurred of doing non-lethal damage with a sword would cause the attack to miss.
This suggested to me that lethal intent was there. Also this player has a habit of impulsive stupid acts when things do not go his way!
Also I am using the alignment bar from the background generator from one of the books, and his alignment started at Neutral 4/Good 3, my planned change would take him to Neutral 4/Evil 7. Maybe I should change to Neutral 4/Neutral 6 instead, just on the border of Evil?
I am an experienced DM, but this is my first AP, and I am taking all of your comments into consideration, so please feel free to continue giving me aid.
Thanks all