Heh, my two most distorted minis ever were my very first Bossk from the original Rebel Storm set and Tion Medon from RotS.

Bossk appeared to have developed an air bubble that went to his head while the plastic was still cooling, grossly enlarging and rounding his head so that it looked like a lumpy brown balloon. His only facial feature were his 2 red with a black dot inside eyes that ran crazily down from his crown to where his chin would have been, sort of like two sloppily spilled red omelets. The rest of his sculpt was perfectly fine.

Tion Medon's top and bottom halves were shaped and painted just fine too but were assembled slightly crooked at the waist. A person might not even notice when Tion's just sitting on the table because of the angle, but if you lift him up for a closer look you can see quite clearly that his left arm, meant to be hanging at his side, is unattached at the elbow. From the mid-forearm up, his left arm is attached at his shoulder where it should be. From the mid-forearm down however, it's attached to his sculpt only by his left hand. The open air separating his upper and lower arm is perfectly in line with the slightly crooked mold line where he's joined at the waist, so the overall effect is that he looks like his torso and arm were just slashed completely through with a lightsaber swing a split second ago and gravity is only just starting to catch up.

I just got a Trandoshan Scavenger, the base at the bottom was awful, the knife was all bent and wavy, and he was brown skinned. Supposed to be green.

I had a Heroclix figure like that once for a character named Blink. Her head was only attached to her body by her long flowing hair, which was attached somewhere between her shoulder blades. I finally just broke off her head, hair and all, and then glued it back together head to neck.

My Cad Bane looks exactly like Nahdar Vebb. I mean EXACTLY. They even included Nahdar's stat card. Can't believe they screwed that up so bad.