I came across this thread a few weeks ago while doing pre-purchase research on the MacBook Air. My wife bought a 13" 128 gb air last November, so I knew that I definitely wanted to purchase one, just wasn't sure if I'd get 128 or 256 gb. I was very distressed to read about the wifi connectivity issues that you all have experienced. It seemed incredible that such a major problem wasn't being acknowledged and fixed by Apple. The idea that users would have to dig deeply into their system to fix a basic problem seemed outrageous. This was almost enough to make me decide to not purchase at this time--despite the sweet improvements to the latest version of the MBAir. In the end though, since I've been pretty lucky with tech, I crossed all my fingers and ordered the 13", 1.7 GHz, 4 GB, 128 GB Air. It arrived 9 days ago and I spent a few hours setting it up, but with a plan in place based on some of the solutions suggested in this thread. I've had no problems so far, so this post isn't offering anything new to those of you who already have the wifi problems (again, my sympathies and best wishes for fixes), but is aimed at people who may be considering whether or not to buy a new MBA, Here's how I did the setup:
I ran Software update on my iMac (it has Snow Leopard as the OS)
I synced my iMac Mail, Calendar, Keychain, Contacts, Bookmarks with my MobileMe account
Before turning on the Air, I used an ethernet adapter and plugged into my AirPort Extreme base station
I turned on the Air and ran setup without migrating anything from my iMac
I did NOT turn on bluetooth or wireless, but rather left the ethernet plugged in the entire time
I ran Sofware update several times until it didn't find anything else to update
I synced Mail accounts, calendar, keychain, contacts and bookmarks with MobileMe
I copied my iTunes music library to the Air and imported all songs
I tested all applications and set up my personal preferences like dock size, wallpaper, etc
I turned on WiFi, located my home network and logged in
I then unplugged the ethernet cable for the first time--the wifi signal held
I tested it by walking all around the house (2 story, horizontal, base station on lower level in far corner room)--no dropoff in signal strength
I turned off the Air and when starting up it found the network immediately and connected, same for coming out of sleep mode.
After a week with absolutely no problems I tested it by taking it to my office in a large hospital. I connected it to "GuestNet" the local network for patient's/visitor's computers and cell phones, and it worked perfectly all day with no lost connections.
So, I haven't uncrossed all of my fingers yet, but I'm encouraged.
Also, I have never turned on Bluetooth
I hope this might help someone who is thinking of buying an Air. Sorry that I can't offer any solutions to those of you already plagued by this problem. Best of luck...