Larry Litmanen :
PCs from Dell, eMachines, HP, Compaq did not have a single component that died, yes they were underpowered but they worked and honestly never even died, we just got better PCs.
Where you get you PSU bad taste is i am guessing here is you bought a cheap PSU before or had one from like iBuyPower. They just put in whatever they have.
The big PC makers are always huge on reliability because for them a single RMA can mean a loss on an entire sale.
I can see from everything you've said here that you clearly do not know how custom built PCs part picked and assembled by very experienced gamers vary from those mass assembled by big name brands. The assembly work is often flawed, and in general, their main priority for picking parts is getting ones they can buy in volume. There are a TON of parts that meet their loose QC standards, and they always go with the ones that they can get at best volume and pricing. Add that to requiring consistent, high volume suppliers, and that is why the parts they use often fits a narrow market profile, NOT because they're higher quality. Seriously, it's as if you've never heard the expression quantity over quality. That's what name brand PCs are.
I'm also willing to bet in those name brand PCs you're referring to having experience with, you've never owned one the likes of this, which has smallish case with poor ventilation, very powerful GPU, and under powered PSU. All 3 those factors combined spell trouble, and experienced custom game PC builders see those things right off the bat. You also have to be an avid vs casual gamer to really put a gaming PC through it's paces, otherwise the success rate is skewed. Clearly you're talking like a casual.
Another misconception is having to send the build back to the seller. If it were to have a retail box vs OEM CPU, that would not be necessary, because Intel would honor the 3 year warranty on it and identify it by it's serial number. If you're really THAT experienced with PCs, especially powerful gaming PCs, you'd know that.
I'll grant you that the price is better than most name brands would offer with parts like that, but the general rule of thumb with name brand PCs, is if it's too good to be true, it generally is. I could come close enough to that price with holiday pricing to easily make the slight extra paid well worth it in better parts, and better warranty support. That's the whole point you're missing. You're only looking at price and convenience, the two things that make such mediocre companies so powerful in the first place.
Have you looked at the quality of HP printers lately? They're very fail prone. HP used to have some of the most reliable printers. Bigger is not automatically better. It just means they sell more product and thus have more overhead. If anything bigger companies are more prone to QC problems, especially in times of recession when people buy less.