Paulie - all those shigans and further injuries.
Pell too true.
Everybody's mentioning Wiper( because of previous injuries and using the reject dial so many times.) and i would agree but adding to him with the very nearly anyone WEAK who got hit by lightning, excluding Zolo cause he's tough. But the SkyKnight should have definetily died from lightning strikes on his metal armor even if he had insulation. And Robin
Oh hell yeah Conis's father should have died.
Nami- her suicidal stabs in the arm whenever she lost hope against Arlong.
Zolo - All the times Luffy has "switched" with him or pulled him somewhere into walls and the ship. don't know how he possibly haven't died., not to mention getting lost and never making it anywhere going in circles and dieing of old age never having fought most people.
Usopp - The amount of times he got dropped or bumped or electrocuted, or thrown or bombed or scarred by Jyabura (Franky, Franky family), basically in the Enies Lobby and Water 7 arcs alone. Even though he was wearing one giant bandage, think of the reason he was wearing that giant bandage.
Definetily Lucci (obviously), Croc (punched upwards through solid bedrock, multiple times) ,Kumadori (long haired overdramatic CP9 who got seemed like he got killed by Monster Point Chopper), oh and the Spand - bum
Oh I think Bellamy should have lived so that Luffy could have constantly been given the opportunity to pwn Bellamy if he was like just feeling in a bad mood.