My favorite from a SF Member who looked like she slathered her regular make up on with a paint brush and roller -
"I can't use Cammo paint; it makes my face break out!"
LOL!
During NBC training when we were putting on the MOPP gear, I also asked, "Don't these come in a better color? This bright yellow really just doesn't work for me."
Once, at Shield in '07 when we had just run into a bunker during close-in IDF, it was all nervously quiet for a minute. I (the only civilian in there) broke the silence with, "Damn, I broke a nail!"
The guys all cracked up and a Colonel said "Thanks. I needed that!"
If you don't have a sense of humor, you'll never get through these deployments. :)