Worst intentional name?
Probably the dwarven Psionist a friend made around the same time the psi hb came out...
Death Monkey.
Worst unintentional? Well, a friend of mine has always had a bad time thinking up char names... one time, ina pinch, the DM asked him "Hey Dylan, what's your char name? I need it." "Oh... Umm... Bob for now, I guess..."
Henceforth, his character was called Bobfornow.
Kinda funny, really.