Neither warlord (or pally) Cha to saves or maneuvers are needed to achieve 29+ to your saves. And as is usually the case, also in the final fight against Orcus you actually only need to worry about a high Fort and Will, not Ref, and only to (Su), (Sp) and spells, most notably vs fear (Will DC 41 aura) and death (Fort DC 40 on melee hit with Orcus' wand). Here are some example numbers from two initiator builds I've previously posted on GitP, both admittedly intended as defenders, but optimized mainly for melee control and active defense (not for high passive defense numbers specifically):
Nelly Nephilim Monk 1, Warlord 1, Wilder 1, Warder 1, Zealot 6, Awakened Blade 10:
AC 52, touch 22, flat-footed 39; +5 dodge vs traps
(14 armor, 8 natural, 8 shield, 2 Dex, 5 deflection, 6 insight, 5 dodge, -4 size, -2 rage)
Fort +34 (8 Con, 3 awakened blade, 2 monk, 2 warder, 2 warlord, 5 zealot, 5 resistance (pauldrons), 1 competence (pale green prism), 6 insight (Stance of the Inner Eye))
Will +35 (5 Wis, 5 awakened blade, 2 monk, 2 warder, 2 wilder, 5 zealot, 5 resistance (pauldrons), 1 competence (pale green prism), 6 insight (Stance of the Inner Eye), 2 morale (rage))
+5 profane to AC and saves vs attacks and effects caused by shaken, frightened, panicked or cowering enemy (Black Seraph Style)
Combat Reflexes, uncanny dodge & improved uncanny dodge, 55' melee reach, dirty trick CMB +75 (also as AoO), Improved Trip CMB +92
Eddie Pincerhand (progressed to 20th) Monk 4, Warder 10, Barbarian 2, Formless Master 4
AC 50, touch 28, flat-footed 41
(15 armor, 10 natural, 7 shield, 4 Dex, 5 deflection, 5 dodge, -4 size, -2 rage)
Fort +30 (8 Con, 3 barbarian, 4 monk, 7 warder, 2 formless master, 5 resistance (piercings), 1 competence (pale green prism))
Will +29 (7 Wis, 4 monk, 7 warder, 2 formless master, 2 resistance (piercings), 1 competence (pale green prism), 4 insight (crystal mask of mindarmor), 2 rage)
+5 profane to AC and saves vs attacks and effects caused by shaken, frightened, panicked or cowering enemy (Black Seraph Style)
+5 to saves vs mind-affecting (Abomination Shift)
+4 to saves vs fear (
rallying armor)
50% chance to avoid SA or crit damage and effects (Sensory Shift)
SR 20, ignores first 12 death effects (
Scarab of Protection)
Combat Reflexes & uncanny dodge, 55' melee reach, grab CMB +84 (maintain as AoO), Greater Trip CMB +93
Note that it's unlikely Orcus can activate his aura of fear before he's at the very least shaken if fighting either of the above example builds (meaning they both will likely make the save on a roll of 2+). Both these builds also have access to maneuvers to increase the above numbers considerably, such as Lord of the Pridelands (Golden Lion 9th) for up +10 morale to attack, damage, AC and saves for one round, and both may initiate that maneuver each round and still typically have a
lot more actions left than Orcus has per default. IOW, I'd sure put my money on Orcus and his cronies being the only ones peeing their proverbial pants in fear in a fight against either of these two. (For a more detailed example opening round in a high CR encounter, check out Nelly above against the CR 30 demon lord Pazuzu and three CR 25 balor lords
here.)
Sure, but at that point the whole tromp l'oeille idea has become highly dependent on GM fiat rather than hard RAW, and therefore it has most likely also been reduced to not much more than a weapon to use on the final levels rather than a strategy to solo the entire adventure. And at least AFAICT from skimming through the adventure, those final levels are probably going to be the easiest for an optimized PC (or party) regardless of any aid from a construct copy of Orcus.