What's your worst rebuilding #$@%!! "facepalm" mistakes?

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After you've put a saw back together and see a circlip laying on the bench is a bad feeling...
At least you found it before you tried to run it. Yeah, that would suck, but that level of suck is far less than porting the saw or opening up the transfers as the wrist pin slides out.
 
Here is my addition: I decided to rebuild the 390xp I talked about in the "How many have you... crushed?" Thread. I had another parts saw laying around so I started putting together what I had, made a list of what I still needed, and off to the saw shop I went yesterday. I got a used crankcase, seals, gaskets, bearings, tank assembly, and a used starter housing. $325 bucks or so later, and I started putting her back together yesterday afternoon. The only thing that kept me from getting it going yesterday was I needed a dang plug wire. After I went to bed, I remembered the 576xp bucket and after work today I robbed the coil off it. Got it all buckled up and she hit on the first pull and started on the 3rd! After idling a few minutes and the some half throttle revs, I opened it wide open and POW! It just died and I could hear SOMETHING still spinning inside! My first thought was "THATS JUST FRIGGING GREAT! Ive spent all this time and money bringing her back to life and Ive royally screwed something up!" Turns out, it wasn't THAT bad, I had forgot to tighten the nut on the flywheel and it backed off and sheared the key. 5 minutes later and after another flywheel was installed, she roared back to life!
 
After you've put a saw back together and see a circlip laying on the bench is a bad feeling...
Well, the one lying there it could be the one that you removed. The other two new ones that you installed may be attached and OK. When removing a piston, I usually only remove one and then knock the wrist pin out.
 

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