I have 2 airport expresses (v.6.3) 802.11 b/g and am trying to get one to extend the range of another. When using the Airport Utility to do that, it gives me an error and tells me to restart the Airport Utility. I've tried manually setting it up dozens of times
Since these are older "b/g" devices, you'll need to use the WDS configuration method on all of your devices. This is a tricky setup for most users because it's really easy to make a mistake in the process.
You will set up one device as the +WDS Main+, and depending on your requirements, both of the AirPort Express devices will be setup as +WDS Remotes+ or if you need to cover a long area, you will setup one AirPort Express as a +WDS Relay+ and then other as the +WDS Remote.+
Expert user Tesserax has previously posted detailed instructions for both the Main and Remote, and Main, Relay and Remote configurations. Check out the two links below for more info. If you have further questions, it would be best to start a new thread since the topic of this thread focuses on using the newer "extend a wireless network" feature.
http://discussions.apple.com/thread.jspa?threadID=2287950&tstart=0
http://discussions.apple.com/thread.jspa?threadID=2422028&tstart=0