Concerning the worst things that could happen to aspirants before becoming Space Marines, there are probably innumerable horrible ways to die from the different implant processes.
Take something as simple as the Larraman cells that provide a marine with fast-clotting blood. It sounds straightforward, but in reality people die today from blood clots when their regular clotting process (which already involves dozens of different cells and chemical signals) goes wrong. The Larraman cells must have even more complicated triggers in place to keep from killing you. I would imagine that unless, as an aspirant, you had exactly the right genetic markers, and your implant was accepted perfectly, you could wake up from the surgery and have all your blood immediately clot in your veins. Pretty crappy way to die.
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