I finally came up with a toon (after just 2 slots but many retcons) that is actually utilizing more than 2 or 3 build slots.
In Alerts I almost always tank with him and that is his design. (Build 1)
If someone else wants to tank I switch from a Defense Passive to an Offense Passive in either Ranged or Melee Role (Builds 2 & 3) and deal decent dps and maybe do some offtanking & cc.
When I Gravi I may run in Hybrid Offense Passive mode (Build 4).
In Andrith I had good luck going in Hybrid Defense Passive mode (Build 5).
When his gear and build and my practice with him is more solid I want to try tanking Gravi's again. I've contributed to some wins in Tank role but I couldn't hold agro and I was pretty glad at the time so I've left this tough Gravi role to the better geared/tuned pros for now.
It might be useful to add a build or two that swaps out gear, too. Not got that far yet. For example I have Dex as a SS but I don't have any gear with points in it due to his primary thing is being Tanky with Str & Con. I could dump a bunch of Con for Dex (Build 6) on those runs where we just need raw deeps.
I've tried running Kos in some different builds but I always end up going back to the same 2. Support Role - defense mode w/Aura of Give everyone dmg resistance, or, Support - offense mode w/Aura of Give everyone + dmg. Whether he teams or is solo. And they work perfectly, no desire for more. To this point anyway!