Get a passport asap. Is she a dual citizen? If so, even getting her a UK passport probably wouldn't stop him getting a passport based on his home country. This may sound outlandish, but I would check with the possibility of you being able to get her passports for both countries, that way all bases are covered.
Diary everything, record DD if possible (discreetly, of course). If she comes back dirty or sore, take pictures. Again, be discreet. You need evidence. It doesn't have to be evidence that can be presented in court, just evidence that you can show police or authorities, even if they can't use it.
See another solicitor, a different one. You can get another free 1/2 hour. Discuss specifically the pros and cons of legal orders vs your non-formalized arrangements. Also, here (US) it is very common to have a 'non-disparagement' clause in a case like yours. Shit-talking legally results in stopping contact and the 'guilty' parent must go back to court to re-start it. Non-disparagement also covers extended family and it is expected that the parent will rein in other relatives or keep the child away from them.
There was a mother on another thread who was able to stop the father from picking up at school by telling the school not to allow it. She didn't have any type of orders. Talk to the school.
You may have to consider dropping your course and picking it up later if you truly have no other options when it comes to childcare. Again, to me it would all have to do with how much longer you have.
And finally, again, do consider relocating. I think you'd be better off surrounded by strangers and away from him/his family than surrounded by friends/family and having to deal with them.