My nomination goes to the driveshaft cutout in a mini subframe, that is a quarter inch smaller in diameter than both the pot joint, and the CV joint, making removing a driveshaft as a complete assembly with boots not possible.
I can just imagine the engineer designing the thing, sitting there with an evil laugh.
Rotten little bugger.

Remember the subframe was designed before Pot Joints were even used.

The engineer designing the pot joints was sitting there with an evil laugh

Some times engineers do have the last laugh. So do software designers.

The poeple who wrote the software that operate scanners attached to computers where of that ilk. They called the drivers "twain". It simply stands for "technology without an intelligent name" - true story.

Yes I can see a couple of pomgolian engineers chuckling with strong northern british accents saying "this will fix the boooggers"

Mike

CVs will fit through most subbys OK but pot joints won't, unless it's a late subframe.
I fitted pot joint shafts complete with both ends into Barney but had to pass them through the subby from the inside, outwards.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

just make the hole bigger

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Starlet Conversion:
http://www.ausmini.com/forums/viewtopic.php?t=15484

You mean just throw most of the subby away, as you converters do...

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I've never managed to tighten a choke cable inside the car, and can't work out how to do it. However, that may be a function of me being thick and not a design flaw. Might weld it in next time.

Plus I broke a vital component in my wife's Estate: the clothes peg which holds it open.

BMC - B@st@rd Motor Corporation.......
years of designing to make simple things complicated...

Where do you start /stop ?

Engine out to get to the diff....
Flywheel off to change the clutch....
Engine out and flywheel off to take off gearbox.....
Fanbelt and / or Radiator changing ......

...but then you get to drive them....

What other car can you do a clutch job on without removing motor and/or gearbox?
Only one I can think of is a Camira... probably its only good design point.

BTW I had a look at a VW turbodiesel caddy today, only thing under the bonnet you can get at is the alternator!!

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I changed a clutch in my Morris 1100 a couple of weeks ago and it took 1 hour, 45 minutes. I was taking my time and cleaned and checked everything. How many front wheel drive cars can you do that with?

I know of some new cars that you need to pull the inlet manifold to change the spark plugs.
I know of one new car that you have to remove the motor to change the spark plugs.

Minis are easy by comparison.

The VW beetle has a pull-cable for the bonnet/boot (the one at the front of the car) that is in the glove box. If the cable breaks or gets too stiff and won't open, you have to smash the handle on the boot to get in (apparently).

The windscreens on new cars suck - My friend's Land Rover Discovery has a seal around the windscreen that you have to cut to get the windscreen out. It costs $200+ for a new seal (from Rover). Daihatsu charades from around 1990 have a glue-in windscreen (along the top edge) that can't be removed without breaking it (so we were told anyway).

The Suzuki Baleno has a problem where the bolts holding the gearbox onto the engine come lose and fall out. the weight of the gearbox is then supported on the input shaft and it trashes a bearing in the gearbox.

I thought this post was about clubbies

Whats that? You drive a moke?

you assume the Moke actually had design process - I think more an accdicent with a set square.

after too many years on Jags
Minis and Mokes appear well thought out
Some of the designn features from Browns Lane I have to manage overthe yers

-Rear bumpers that can only be removed by taking the Fuel tank out
-Windscreen washer nozels that can only be replaced byremoving the the entire dashboard
-Spark plugs that can only be replaced by removing the air conditioning compressor and the inlet manifolds
-Triple carbies with a balance pipe to the brake booster (think about it)
-In board rear brakes