My church has a 16-port version of your failed one and it's been problematic since they bought it. Maybe it is oveheating; I hadn't thought of that.
As for other adventures - I bought a wireless print server that still has some pretty serious bugs in the firmware. It's DHCP client wouldn't stay switched off, for instance. And I have a PCI wireless card that comes with a connection utility that likes to hang Windows 2000 :-/.
What's worse is that I have a Access Point and PCMCIA card both from NetGear that are quite a bit older and work very well. I guess they must have been cutting corners on quality control since.
Wade.