Actually I ended up opening a ticket on the 20/40 switch while in Range Extender mode locking up the Almond.. Seems it might be reproducible ..
Not sure why the reset button didnt take on the first try... plugged it in while holding it down.. the first time it just froze.... waited a bit when it wasn't moving...
Unplugged it again.. let the screen blink then held it down for 10 sec... Got a dialog box saying resetting.. waited roughly 30min.. said forget it.. rebooted it again and didnt touch anything... slight delay but the router came back up and finally showed the home screen... went to the web UI, set the timezone, and did a reset to defaults and seems ok since..