A few nicknames I've come across over the years:
BUM - Brigade's Ugliest Man
Samsonite - so called because he was always carried by everyone else. See also Gerber - a useless tool that everyone carries.
FONC - Friend Of No C....
BUFFY - A certain postal Sgt on Telic 1 - Big Ugly Fat F....... Yeti
PORG - Person of Restricted Growth
FIGJAM - F... I'm Good Just Ask Me
And these were the more pleasant ones.........
