I like this idea of Two-Hit Minions from Dungeon’s Master. First hit bloodies the minion, second hit destroys it. I think that would make minions more interesting and useful. The comments on the Dungeon’s Master post are also worth reading for more ideas.
Even if I do switch to Pathfinder for some games, I will probably still use minions. I just like the idea of PCs blasting their way through a crowd of mooks while fighting the boss.