No really 'crazy' stories here, though I can relate to Al's anecdote about using all 12-gauge wire just because we have a ton of it.
And we've definitely helped several teams put together their box on wheels. I originally thought someone was talking about 116's rookie year and their first trip to the Championships in Orlando.
Here Dave recounts tales of doing just that (but for different reasons) and how a team helped them put it together.
2007, we were 0.1lbs under the limit. The inspector at VCU kept messing with us by tapping the robot, making it go over the limit by 0.1lbs.
In general in FTC, zipties and loose cords fail the sizing rules for teams just as much as teams who have frame members beyond 18". It's more of a "doh!" moment though.
DC Regional, 2010. The lead inspector told us his interpretation of the intent of the digitization of the BoM, which was so that FIRST could create statistics based upon usage and create next year's KOP accordingly. So as we were off to create an Excel file that would meet those implied needs, he tells us 'Just scan your paper copy in. They didn't specify what digital format!'