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Heres the setup:

Base station:
WRT54G V3 with latest HyperWRT+Thibor

Remote station:
WRT54G v5 with latest DD-WRT

One XBox wired to each router (I did try this with my 360 to see if the fact one of the XBoxs hadn't been updated with the latest Halo 2 XBE made any difference, it didn't). I can FTP to both on both XBoxes without a problem and they definitely get internet connections as shoutcast works fine on XBMC. Halo 2 will pick up the other XBox's game but when it tries to connect it hangs at joining game and then closes 5 seconds or so later.

Signal strength was at 40% reported by the router and I got a sustained 1.5mb/s at 1ms ping. Anyone got any ideas on why it won't join?