So I tried the manual, first point of call, and no luck.. I just have it for the printer and occasionally itunes.

I can't get it to work, and tried to hold the reset button down with a pen for 5-10 seconds. any help would be much appreciated

Hate to say it, but it sounds like your Express has had it. Join the club

It sounds terminal...

I've seen a few pages on the web about resurrecting them.. but it involves cracking them open and doesn't look easy..

The 24" iMac or Macbook Pro in your signature is still under standard or extended warranty?

If so take it to a Apple service agent and Apple will replace it if it turns out to be dead. My completely dead (no light and burnt smell) and out of warranty Express was replaced with a new one a few weeks ago.

you're shitting me right?

Your AirPort Express Status Light Flashes Amber
The Ethernet cable may not be connected properly, AirPort Express may be out of
range of an AirPort network, or there may be a problem with your Internet service
provider. If you are connected to the Internet with a DSL or cable modem, the modem
may have lost its connection to the network or the Internet. Even if the modem seems
to be working properly, try disconnecting the modem from its power supply, waiting a
few seconds, and then reconnecting it. Make sure AirPort Express is connected directly
to the modem via Ethernet before reconnecting power to the modem.


If your AirPort Express is set up in a WDS, the WDS link may be interrupted.
Note: If AirPort Express is set up as a wireless client and the network it's joining is
protected by an access control list (ACL), AirPort Express must be in the ACL to connect
to the network.


Tips and Troubleshooting

To return AirPort Express to the factory settings:
m Use the end of a straightened paper clip to press and hold the reset button until the
status light flashes quickly (about 5 seconds).

I should make a note that I did that, what happens right.. is that it goes green, then orange (doesn't flash) for about 30 seconds or so, then it starts flashing in one second increments. holding the reset button down didn't do squat.

AirPort Express restarts with the following settings:

 AirPort Express receives its IP address using DHCP.

 The network name reverts to Apple Network XXXXXX (where X is a letter or number).

 The AirPort Express password returns to public.

If you used AirPort Admin Utility to create profiles for your AirPort Express, they are
preserved when you reset your AirPort Express.
If you need to return your AirPort Express to the factory settings and remove any
profiles you have set up:
1 Unplug AirPort Express.
2 Use the end of a straightened paper clip to hold the reset button while you plug in
AirPort Express.

Guys, I think that when they die, they really die - burning smell, no light etc.

Likely that you just needed to power-cycle everything, check cables etc.
If you sit your MBP down near the AX and hit the airport icon, do you see a network called 'Apple Network 8F3E5A' or similar? If so, then you just reset it and so need to join that network, open the airport admin utility and restore the old profile

Doesn't sound like it's dead mate - just confused..

Jeremy

well it's working now, just had to press harder on the reset button (didn't want to break it or nothin).

cheers for all your kind help folks.

Cool. I was also going to suggest that maybe 5-10 secs wasn't enough. I seem to remember having to hold it in a lot longer (like, 30 secs) last time I reset mine.

What sort of life does the Express generally have? I was looking at getting one, but if they're temperamental or unreliable, i'd need to think twice...

I reset an Airport Express to factory settings recently (sold to relative).

This page had a different factory reset procedure:

http://docs.info.apple.com/article.html?artnum=108044

How to perform a factory default reset

Important: This erases all settings and saved profiles. The settings erased include Access Control and RADIUS settings.

Follow these steps:

Unplug the AirPort Express from the power outlet.
Press and hold the reset button.
Plug AirPort Express back into an AC outlet (still holding the button).
Continue holding the button until you see the light flash green four times, which should happen after a few seconds.
Release the button.

yeah the problem was that I got a new router, and the computers couldn't find the airport on the network.. no biggy

Great to hear it's still working mechcon... fingers crossed you get a decent useful life out of it.