Airport Express dropping out constantly so I can't print wirelessly

I have an iMacG5 running OSX 10.3.9. I have a DLink wireless router which creates my wireless network that the iMac connects to. Also, as my printer as at the other end of the room, I have an airport express connected via USB to the printer so I can print wirelessly. Everything worked like a dream for about 12 months. Until recently I had no security on this network and although I was aware this was risky, I was reluctant to change anything because it all worked so well. But my paranoia got the better of me and I changed the DLink to WPA security. Ever since then, the airport express has acted very strangely. The connection dropped and I was required to do a hard reset. I did that and everything worked. I felt so smug that I had worked out a computer issue! Little did I know that as soon as I shut down the system the airport express dropped out again. I have since discovered that I don't actually need to shut down for the thing to drop out. It just does it of its own accord.
I have contacted AppleCare 3 times and spent a total of about 4 hours on this to date. No luck. They suggested interference. However my airport icon usually shows either 3 or 4 bars and there is no difference when the thing drops out.
The only thing I have learned is that Airport Express does not have to be reset all the time. In my situation, it is best to just unplug it, let it rest for about 30 seconds and then you should be able to see the thing in the airport admin utility. It does take a while and several rescans in the utility, but eventually it does show up. This at least means I don't have to constantly set it up to join the network.
In fact, really it is a doddle to print! I don't know why people like to just go File-Print when you can go through the delight of getting out of your chair, unplugging Airport Express, waiting 30 seconds, looking at the dust under the cupboard thinking I really must get that, plugging the airport express back in, watching the light change from green to amber, to flashing amber, wait for it...wait for it...it's not happening....waiting...finally - green!. Back to the computer, go to Finder - Applications - Utilities - Airport Admin Utility, not showing up, rescan, not there, rescan, rescan, rescan, still not there, rescan, oh good, airport express is showing up. Now, go to Printer setup utility, delete the printer that is there, then add printer, select rendezvous, add my hp, OK......now I can hit File - Print.
Has anyone got any ideas on how I can join the boring legions of people who are oblivious to the joys of printing my way?

Hi,
I am currently replying to this as it shows in the iChat Community.
I have asked the Hosts to move it to Snow Leopard  (you should not lose contact with it through any email links you get)
I also don't do Wirelss printing so I can't actaully help either.
10:01 PM      Friday; July 29, 2011
Please, if posting Logs, do not post any Log info after the line "Binary Images for iChat"
 G4/1GhzDual MDD (Leopard 10.5.8)
 MacBookPro 2Gb( 10.6.8)
 Mac OS X (10.6.8),
"Limit the Logs to the Bits above Binary Images."  No, Seriously

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    Please, if posting Logs, do not post any Log info after the line "Binary Images for iChat"
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