Fun one from this week:
Audi TT fwd w/ an aftermarket turbo kit came in for a busted motor mount. Got the car on the lift and realize motor mounts not busted, but had lost a bolt and broke the other. Replaced the bolts. Easy peasy.
Notice one of the coolant lines to the turbo is rubbing on the CV shaft, go tie it out of the way and it breaks off at the crimp fitting and i take a blast of 200*+ coolant to the face.
Go to pull the banjo fitting off the turbo and notice one of the exhaust housing bolts is backed out against it. Spend forever retightening it.
Get the Banjo fitting off, cut off the crimp section, trim back the cooked coolant line and reattach everything w/ hose clamps.
Notice that the compressor side / center section is still loose. Its missing another bolt and 2 more are also backed out.
Try to tighten them, realize that the turbo is more then just loose, its got a massive amount of clearance between the center section and the exhaust housing, like someone put the wrong exhaust housing on the turbo.
Turbo is destroyed because the exhaust wheel has been knocked against the housing millions of times. Coolant lines need to be redesigned. Intercooler piping is made from hacked together steel tubing. Silicone couplers for the aftermarket kit have been hacked to oblivion. Oil supply and return lines are questionable. Intercooler / intercooler mounts are also probably in need of additional work.
I want to punch the company that made the kit, and I want to punch the people that installed it / built the intercooler piping.
Customer was expecting a $250 repair, the bolts made it a $30 repair, but the turbo stuff will add at least $1000 back onto that.
Oh, and my coworker picked it up from the customers house, and while driving down the highway someone whipped change at the car and shattered the wind screen behind the seats. (he had the top down because he follows my "having the top up on a convert is NOT COOL" mindset)
Amazingly, dude was totally cool about it all. Hes going to check if he has glass coverage and save up till he can do the turbo stuff.