Darth Jello
Cheese Spelunker
Maybe we should compile a list of injuries?
I'll start. This is gonna be incomplete because I'm goldbricking at work and won't be home for a few hours. I'll fill in some of the missing ones since I have pretty much all of his earlier appearances at home.
DD #161- Suffers a nervous breakdown due to brain tumor
DD #189- Concussion (head smashed against railroad track). Tumor removed.
DD #181- Falls off high wire onto train track with twisting motion. Multiple broken bones, spine severed at C3.
DD #200- Concussed after repeated blows to the head.
DD Predator's Smile- Shot repeatedly (stopped by kevlar suit). Beaten unconscious (if I remember correctly).
DD #190-Beaten unconscious by Daredevil
Punisher v3 #1-Shot through both hands.
Deadpool #28- Impaled in chest by boomerang shaped piece of metal (don't remember what it was off the top of my head).
DD-Guardian Devil- Front teeth knocked out by DD's club.
DD-Hardcore-Several teeth knocked out by DD. Concussion (head smacked against pavement. Tattoo carved into forehead with sharp stone by DD.
Greatest Hits-Fake tooth knocked out.
DD-Murdock Papers- Thrown out of window, several teeth broken, hit by a bus breaking several ribs and both legs.
DD-Devil in Cellblock D-Beaten unconscious with rifle butt.
Thunderbolts-Faith in Monsters-Neck snapped by American Eagle, speech center of brain fried with nanochains.
To be added later-other DD appearances, Streets of poison, Punisher countdown.
Also, keep in mind that everything before DD #198 or so has him as a regular old baseline human with no metal bones or enhanced abilities whatsoever. Just a lot of training and an armored suit.