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So I am
Hellknight requirements PFS
Base Attack Bonus: +5.
Skills: Intimidate 5 ranks, Knowledge (planes) 2 ranks.
Armor Proficiency: Must be proficient with heavy armor.
Alignment: Any lawful.
Assume build to Lv. 12
Class levels
6 levels Bloodrager
Pros
We are looking at a movement increase, Full BAB, rage bonus, some spells, and a dip into bloodlines. We would only be getting the first bonus feat however. Intimidate being a class skill as well as getting 4+ int skills per level allow us to have dumb int to an extant. Bloodlines like elemental allow us to get knowledge planes as a class skill as well. They are both Chr. based casters so we should in theory be able to pick up a few decent spells as well as also potentially dumb Wisdom. Uncanny and imp uncanny are great in all forms of situations.
Cons
However we do not have access to Heavy armor proficiency, taking up another feat. While we will have blood casting we only have four first level spells ever
Will saves will be awful being bad saves for both class, with feats, traits, or a decent Wisdom score the only way circumvent.
Only 1 bonus feat through 6 levels is rough, forcing delaying taking HellKnight a level earlier.
6 Levels Hellknight
pros
Cons
Feats
I'm still working on this, but if you have ideas I figured I'd get the post up so dicussion could potentially start. Leave any ideas on how you would build your hellknight and why. I would love to have a solid guide out their for this class.

UnArcaneElection |

^Yes,Steelblood Bloodrager gets Heavy Armor proficiency (and no Arcane Spell Failure) right at the start, and while it trades out Fast Movement at 1st level for Indomitable Stance, it starts getting it back at 2nd level (in exchange for Uncanny Dodge), and gets Armor Training (as the Fighter class feature) at 5th level (in exchange for Improved Uncanny Dodge).
The problem with going Bloodrager into Hellknight is that Hellknight doesn't progress spellcasting, which is a significant Bloodrager class feature that is especially hurt by not being progressed. Hellknight Signifer does progress spellcasting (and doesn't even require Heavy Armor proficiency to get in -- it gives this to you at 1st level of the prestige class), but going to d8 HD and 3/4 BAB isn't worthwhile when you are progressing 4/9 spellcasting (not even very good with 6/6 spellcasting, but maybe worth considering for a dip). Also, to get into Hellknight Signifer as an arcane caster, you have to have Arcane Armor Training, which is just bad.
Maybe the upcoming Path of the Hellknight will give us some better options. (I'd really like to see a Hellknight Stormtrooper archetype of Barbarian that overrides the normal anti-Lawful restriction of Barbarians and gives you Heavy Armor proficiency so that you are ready to go into Hellknight as long as you put in the required skill investment and pass your initiation rite.)

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Hellknight Commander: HellRager Build
Hellknight requirements PFS
Base Attack Bonus: +5.
Skills: Intimidate 5 ranks, Knowledge (planes) 2 ranks.
Armor Proficiency: Must be proficient with heavy armor.
Alignment: Any lawful.
Race
Human: Being able to choose where your racial +2 is going is always beneficial. Bonus feat is arguably the best racial bonus in the game. Human is a solid choice for any class that exists
Half-Orc: +2 again, Increase in intimidate and darvision are nice. Consider the alternate racial traits of the following if you are interested in building a Half-orc. Orc Atavism, Sacred Tatoo, or skilled
Dwarf: Con and wisdom are both generally useful stats but losing con is going to change are stat buy. This class is less optimal then the previous two, but still doable.
Ability Score
Str: 20__________________Str:18_____________Str:16
Dex: 12_________________Dex:12_____________Dex:12
Con: 14_________________Con:15_____________Con:14
Int: 8___________________Int:8______________Int:14
Wis: 7__________________Wis:7_______________Wis:7
Chr: 12_________________Chr:14_____________Chr:14
Traits
There are quite a few useful traits for many different reasons. So many in fact that while i will list a few this is merely a recommendation based on my preference than a hard set optimal group.
Reactionary is my most selected trait on any character. Going before the enemy is one of the most advantageous things in combat. Bully and dangerously curious are both solid options as well. With few skills per level and a mediocre charisma having UMD as a class skill to allow wands of your sorcerer spells is always helpful. As a hellknight intimidate will be an extremely important skill and if it increases that score then it is always worth consideration. Note that there are traits that accomplish these same things and when making a character it is worth giving them a look.
Assume build to Lv. 12
Class levels
6 levels Bloodrager
Pros
We are looking at a movement increase, Full BAB, rage bonus, some spells, and a dip into bloodlines. We would only be getting the first bonus feat however. Intimidate being a class skill as well as getting 4+ int skills per level allow us to have dumb int to an extant. Bloodlines like elemental allow us to get knowledge planes as a class skill as well. They are both Chr. based casters so we should in theory be able to pick up a few decent spells as well as also potentially dumb Wisdom. Uncanny and imp uncanny are great in all forms of situations.
Cons
However we do not have access to Heavy armor proficiency, taking up another feat. While we will have blood casting we only have four first level spells ever
Will saves will be awful being bad saves for both class, with feats, traits, or a decent Wisdom score the only way circumvent.
Only 1 bonus feat through 6 levels is rough, forcing delaying taking HellKnight a level earlier.
6 Levels Hellknight
pros
Most of what we are looking to get out of this class is achieved in it's 3rd level. We also however want to access his first discipline as soon as possible. If wishing to switch from this level progression I recommend taking 3 Hellknight levels at Character lv. 6 then switching back to bloodrager after.
Cons
Taking more than 3 levels of this class really don't give us much. You are here to play a hellknight, get it quickly and get what we need out of it. If you can get along without the bonus feat at lv. 6 then take hellknight at lv 5.
Feats
These are in not particularly in any order however some are needed before taking hellknight. Note following this build you are currently looking at a total of 7 feats, 8 if human, and 1 bonus feat. Bolded are extremely recommended or needed.
Power Attack: If you are a strength class and are not taking this then you are doing something wrong. This will always bee your first level feat.
Heavy Armor Training:pre-req, hold of on this until your 7th level feat as you won't likely be using you hellknight plate until around then anyway.
Toughness: If you have the extra feat to drop on this take it.
Heavy Armor proficiency:It is a prerequesite, it's nothing crazy. Take it when you feel comfortable to switching to a heavy armor.
Exotic weapon proficiency(bastard sword): It is a great option in a class that will be able to switch from a one handed or two handed fighting style.
Skill Focus:Intimidate: Do you want to use the Fearsome Discipline take this with the following two feats and you will most likely break the game. Assuming your big bad isn't immune to fear.
Cornugon Smash: unless you want to not use fear to avoid the cheese, take this at lv. 9. The shaken condition isn't worth applying, so hold off on this until you can us the discipline.
Intimidating Prowess: again when building into intimidate this is a great choice.
Arcane Strike:Increases damage, if you take this, take it early before your weapons are all enchanted anyway.
Iron Will: your will is bad, like real bad. If that bothers you, take this.
Step-Up: getting to full-round is never a bad thing. this can let you do it.
Combat Reflexes: You have an alright Dex, more AO's is better than no AO's.
Eldritch Heritage,Imp,Greater: Now if you plan on taking this character past level 12 this becomes much more important. We are looking at most likely the entire strength of another bloodline added to our own list of abilities. But note that this is going to cost 2 or 3 feats and shouldn't be done lightly. While i have my preference in bloodlines, you must make sure that you want those abilities these are not feats taken lightly and will greatly impact your PC.
Skill Focus:You will require a skill focus of the class skill given for the class skill of the bloodline taken with eldritch heritage. My personal preference is the Orc Bloodline Eldritch Heritage and Skill Focus: Survival.
Skills
You are going to have very few skill points to use with this build, especially once you start taking levels of Hellknight. You are taking max ranks in intimidate most likely. Perception is the most used skill in the game. You have enough dex for acrobatics to be worth taking. Once you get 2 ranks in knowledge planes you are free to distribute them as you see fit. Just keep in mind the more you diversify with you skill ranks you are going to have a harder time having high enough total modifiers to make checks.
Bloodlines
Eldritch Heritage Bloodlines
Aberrant Bloodline-You arnt going to use touch attacks or this power.
Abyssal Bloodline- Claws are good, but other lines are better for this.
Accursed Bloodline-I guess you could, but your not a witch, let them do witch stuff.
Aquatic Bloodline-A swim speed and a nonlethal attack? If your campaign only did water stuff maybe. otherwise, no.
Arcane Bloodline-You probably are not using meta magic, nor do you need a bond.
Boreal Bloodline-Nothing amazing here, better off with something else to stop cold.
Celestial Bloodline-The ray is cool, and the resist is all right.
Deep Earth Bloodline-The power only working while underground is really situational.
Destined Bloodline-Might be good for a buff caster, but probably not here.
Div Bloodline-If your cool with breaking weapons this is not terrible, but resistance to poison is less common than sire fire or acid.
Djinni Bloodline-10 resistance is good and a ray is helpful, personally I prefer fire, but it is what it is.
Draconic Bloodline-claws and decent resistance, not the best pick but its alright
Dreamspun Bloodline-The ability to cause slumber and a +1 init. Not my favorite but not entirely useless.
Ectoplasm Bloodline-Oooh I can hit ghosts, not worth it.
Efreeti Bloodline-again this is another ray ability and you get resistance 10 fire.
Elemental Bloodline-As far as we are concerned, this is the same as the other elemental bloodlines but you can pick your element. You have this as a bloodrager bloodline. Unless you really want to different resistances I say no to this and all other elemental races
Fey Bloodline- This is like a weird arcane ranger bloodline. Not for this build.
Ghoul Sorcerer Bloodline-In all honesty if you are going to build a claw based attacker, take this. It is what most other give you plus paralyzing. Most other abilities can be gained from an Amulet of Mighty Fists.
Impossible Bloodline-Makes you more effective against constructs, not great.
Infernal Bloodline-The shaken condition is worthless, and resistance to poison isn't worth it.
Maestro Bloodline-We are not bards
Marid Bloodline-Ice element, again the same as others.
Martyred Bloodline-Maybe if you became a healer this would be sub-optimal? For us our healing plans are to have healers
Oni Bloodline-Unless thry let you eventually take the bonus feats with eldritch heritage, not worth it.
Orc Bloodline-and here it is, in my opinion what you should be taking. Your lv.1 ability isn't what we want here but oh boy is the lv 9 good. A full stat increase is worth the grab, sure it costs 2 feats but an ability score increase makes a huge difference. If you take this to lv 17 this is where you blow your greater eldritch heritage. A size increase and massive boost to strength. Arguable the best 15th level ability for a sorcerer bloodline when making a melee build.
Protean Bloodline-Burning a feat for a free tanglefoot bag, no thank you.
Psychic-Applies shaken, not great.
Rakshasa Bloodline-Because you are going to be disguised while rage murdering? Nope on this one.
Serpentine Bloodline-Weak resistances and speak with animals. Not today.
Shadow Bloodline-Your going to be in plate, leave sneaking to the rouges.
Shaitan Bloodline-Acid elemental. Again if you really, really want that damage resistance it's available. But why?
Starsoul Bloodline-This bloodline gives you some super annoying ways to stop your enemies, but with your spell list you will run out of uses fast. Remember this next time you build a sorcerer.
Stormborn Bloodline-Not super great but the 9th level power is one of the coolest in the game.
Undead Bloodline-All right at really high levels but not for us.
Verdant Bloodline-Unless your favorite part about druids are how not great their spells sometimes are you should not take this.
Bloodrager Bloodlines
Aberrant: Extra 5 reach and some effect causing abilities. Not great but the reach isn't useless. Cosider if taking lunge, combat reflexes, and a reach weapon.
Abyssal: The ability to enlarge is good, the bonus feats are good, and the high end abilities are pretty impressive. All around good bloodline.
Arcane: If you really want to try and force a caster out of this build this is how you need to do it. This bloodline will push us into being moderately effective. But there are better builds for this and sorcerers are better for it in general.
Black Blood: Again decent if you plan on using reach to your advantage other wise this bloodline is unremarkable.
The next three are very similar so I am just going to list their effects and then give a blanket statement.
Celestial: Wings, resistance acid and cold, reroll.
Draconic: Wings, breathe weapon, claws, resistance fire, natural armor.
Infernal: Wings, resistance to fear, fire,and poison, flaming weapon
The access granted for wings is good in all three, while similar, the draconic and celestial are arguably better than infernal.
Elemental:Choice of element damage basicly gives use a +1 weapon enchantment 3 times per day, this will stack with our weapon damage. but what your really here for is the 10 resistance in your chosen element.
Fey: Confusing your enemy in combat sounds great, until you realize you just attacked him and now he will fight you until dead.
Destined: Not terrible bonuses but we are looking at +1's when we could be enlarging
Kyton: Not great, much of it involves you taking damage or not wearing armor.
Undead: Again -2 from shaken is all right, but you will be causing fear later on anyway.
Archetypes
The ones you should be considering are the following
Cross-Blooded:So your will save sucks, and I mean it REALLY SUCKS so much so that it isn't unreasonable to throw away all our hope of making them to begin with. So we lose another -2 to our will save and we don't get our bonus from rage. But we do get to pull from two bloodrager lists now, and as most bloodlines have at least one unremarkable ability each this allows us to get the best of both worlds.
Untouchable Rager: One of the biggest bonuses of this class is our ability to cast spells. However we dont get much other than our spell list allowing us to use wands and scrolls. But what if i told you we could become just an even better meat tank and not even worry about pesky spells and their slots. Gives you SR 8+Bloodrager Lv. meaning you will have SR+12 at 4th level. Now getting cured will be difficult but don't completlely ignore this.
Steelblooded: Allows us to get access to heavy armor proficiency for exhanging our fast movement and uncanny and imp uncanny. Personally not a fan of this in the long run as if you stay true to barbarian armor requirements until you start your hellknight levels you really won't run into problems. If you really want to get your Hellknight plate early then take this, otherwise just burn the feat at lv 7.
Again this is just a draft of the full build, please offer any advice or thoughts you may have on the build.

UnArcaneElection |

I think Steelblood is better than you think. Since Heavy Armor is going to slow you down anyway, the fact that Steelblood Bloodrager trades out Fast Movement that doesn't work at all with Heavy Armor for a lesser amount of increase in speed while wearing Heavy or Medium Armor is actually a good thing. (Technically, this isn't a one-for-one trade, because the Fast Movement and Armored Swiftness get trade out and in, respectively, for or from different things, but close enough.) As noted above, the Armored Swiftness ability also works with medium Armor, if you're interested in using that for a while before getting your actual prestige class levels. Losing Uncanny Dodge and Improved Uncanny Dodge hurt, but on the other hand you get CMD bonuses (again, technically not an actual one-for-one trade, as noted above, but close enough) and Armor Training as the Fighter class feature. Armor Training unlocks Advanced Armor Training options (which you can get with the Advanced Armor Training feat at or after 5th level), and while these aren't as amazing as the Advanced Weapon Training options, they're still definitely worth looking at. Also, given that PFS cramps your career space, avoiding consumption of a feat to get Heavy Armor proficiency is not something to be ignored.
With respect to backstory, I'm not the original poster, but sort of related to this, for my homegrown idea of a Hellknight Stormtrooper Barbarian archetype, I had this idea of the Hellknights most closely associated with Thrune (Order of the Rack or maybe Order of the Gate) wanting to develop a super-soldier that combines Barbarian wrath with merciless order, and thus experimented extensively and mercilessly with captured Barbarians to find ways to sculpt their Rage into something Infernally ordered, and finally hit upon the brutal conditioning routine of putting them under existential threat in Hellknight gladiatorial pits (the same ones normally used for Hellknight initiation rituals) to provoke them into Rage while casting Order's Wrath upon them to punish them for any aspect of Rage that went out of control, while stimulating their Rage overall, thus leading to the altered Rage ability being named Order's Wrath after the spell extensively used in their conditioning.
A possibility for the backstory of this particular character is that the Hellknights are still in the early stages of the above-mentioned experimentation, and haven't yet quite gotten what they want, but but have obtained a few partial successes deemed worthy of trial admission to the ranks of Hellknight Armigers (secretly under close watch, of course) for further testing.

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I think Steelblood is better than you think. Since Heavy Armor is going to slow you down anyway, the fact that Steelblood Bloodrager trades out Fast Movement that doesn't work at all with Heavy Armor for a lesser amount of increase in speed while wearing Heavy or Medium Armor is actually a good thing.
Ah now see but here is where you are wrong. We get the bloodrager bonus on light and medium armor, and with the hellknight commander we gain access to Hellknight plate and specifically maintain full movement when wearing it. But it is still heavy so how can we keep the +10 from fast movement? Easy, mithral Hellknight plate, by the time you are wearing it making it mithral should be pocket change. Throw on comfort plus our decreases for hellknight levels and we are well here let's just show the math.
Max Dex +1 Armor Check Penalty –5 Arcane Spell Failure Chance 35%+Mithral=now medium armor
Max Dex +3 Armor Check Penalty –3 Arcane Spell Failure Chance 25%
+comfort
Max Dex +3 Armor Check Penalty –2 Arcane Spell Failure Chance 25%
+Armor Training Trait
Max Dex +3 Armor Check Penalty –1 Arcane Spell Failure Chance 25%
+Lv.2 Hellknight
Max Dex +4 Armor Check Penalty 0 Arcane Spell Failure Chance 25%
And your Dex still goes up from there
So you still have a 25% arcane spell failure, which your shield will be pretty rough unless without enchanting it with stuff, if your using one anyway, but otherwise your pretty good with everything else. Plus if you take Untouchable, then your not casting anyway.
Edit: forgot that Hellknight is already considered masterwork and thus only gets a -2 armor check.

UnArcaneElection |

Okay, I get the plan for avoiding the need for the Steelblood archetype, although the Arcane Spell Failure that you can't get rid of easily will push for using spells that don't have Somatic components (for practical purposes, Silent Spell is out unless you go up to 7th level Bloodrager), unless you go with the Id Rager archetype (which is potentially not a bad idea if you don't mind being shoehorned into its Bloodline replacement). But it would be good to avoid the need for a feat for Heavy Armor proficiency. If you dip into another full martial class to get Heavy Armor Proficiency, you either eat up 1 level of Hellknight, which deprives you of Discipline 2 and Force of Will 2 (so you probably don't want to do this), or 1 level of Bloodrager, which deprives you of a bonus feat (a dip of more than 1 level would deprive you of Improved Uncanny Dodge, which you went to the trouble to get by avoiding Steelblood). So then the question becomes what full martial class would get you something in addition to Heavy Armor proficiency that is worht a feat. Armored Hulk Barbarian is out due to concern over the alignment conflict, and you won't be able to Rage when Lawful anyway; Fighter actually gets you back a bonus feat (unless you take an archetype that trades it for something else, and a subset of these might give you something you actually want); Standard Bearer Cavalier gets you Challenge and Tactician and a Banner (instead of the Mount that won't scale without more levels of Cavalier); Gun Tank Gunslinger gets you a good starting Reflex Save, firearm proficiency and Grit (although unfortunately Gun Tank's Resolve won't scale without more levels of Gunslinger; on the other hand if you DID go to 4th you would get Armor Training); Paladin gets you a good starting Will Save, Smite Evil, and Detect Evil (and the Oath Against Chaos that you will probably have to take changes these to Smite Chaos and Detect Chaos -- the latter will be redundant with your Hellknight abilities, but I wonder if the Smite Chaos will stack properly with Hellknight Detect Chaos or just give an extra non-scaling use, which isn't terrible but not as good). Note that getting a good starting Reflex or Will Save is almost like getting free Lightning Reflexes (not bad) or Iron Will (quite good), which pushes in favor of Gun Tank Gunslinger or Paladin.