Probably not helpful to you now, but a few things you can try if the problem continues when you get it back. This is based mostly on my 27" 2010 iMac. The computer was working good when I bought it, but if came with a free upgrade to Lion so I installed Lion about a week after getting the machine. I immediately started having issues with keys sticking on my wireless keyboard. I though since it was new I just had a bad keyboard. If a key stuck during boot it would not boot correctly. I called Apple and they recommended taking the keyboard in to be fixed or replaced. Since I was using a USB replacement I had on hand I decided to wait until it was convenient to get to the store for me. As I started using my old software I had issues with Lion incompatibility so I downgraded back to Snow Leopard. On a whim I turned on the wireless keyboard and I have not had another issue with stuck keys (It was not a mechanical problem, but a software issue). So if you have a wireless keyboard consider that.
Another thing you could do, though time-consuming is to pull out all your hard drives (unplug all USB devises) and replace with a single hard drive. Do a new install of your OS and try booting and see if the problem occurs. If it does you most likely have a hardware issue. If no problems add one by one your programs and their updates and boot several times as each one is added until you find the conflict. I had to do this on a PC years ago and as I recall it was a video driver that was causing the issue.
Hope you get it going soon. Sounds like a frustrating issue that has been going on way to long. Apple should have been able to resolve this in a more timely manner.
Another thing you could do, though time-consuming is to pull out all your hard drives (unplug all USB devises) and replace with a single hard drive. Do a new install of your OS and try booting and see if the problem occurs. If it does you most likely have a hardware issue. If no problems add one by one your programs and their updates and boot several times as each one is added until you find the conflict. I had to do this on a PC years ago and as I recall it was a video driver that was causing the issue.
Hope you get it going soon. Sounds like a frustrating issue that has been going on way to long. Apple should have been able to resolve this in a more timely manner.