I can't believe that there are people who have had to deal with 3 or 4 bad new machines in a row...I mean I believe them, but I can't believe their bad fortune...heck I buy used Macs off EBay and have never had problems.
I hope things work out for OP, and he is happy with a working PowerBook at one point. I think after the second dead PB, I would have absolutely demanded a new replacement via overnight shipping, and not gotten off the phone until I did (polite or not.) I mean at that point the story was bad but not absolutely horrible, considering that the original rep probably meant for the replacement to be sent out sooner.
I understand that you had a custom-built machine, but personally I would've just taken whatever stock machine is closest, and add later (of course you can't add VRAM later.) If they had actually had the balls to refuse overnighting me a replacement, that might have been enough for me to swear off Apple too.
I don't think actually asking for free stuff will really get you much (with any company.) I don't blame you for asking, but it's like first you tell them this is really important because it's for your work and travel, and then say "well if you give me an iPod I'll feel better..."
I think the main issue is how they could've improved your service during the whole ordeal, and not whether they give you free stuff at the end. I've gone through similar situations with other companies, and make-up type gifts are usually not very substantial.