Call up sony and complain out the ass. Be nice though and explain the situation. As long as you don't give up then you should have a good shot at getting it done for free. Explain how many times this has happened and if they still refuse you could always get pissed and say something like 'smurf this. You guys make defective hardware that is a constant problem for lots of people and you refuse to do anything about it? My next system will NOT be a playstation system, thats for sure. I am going to get an XBox. They have just as many game and many of the same games on there as you have on yours.'

Before you say that last line as to talk to a manager/supervisor first.