A while back we open sourced Komodo Edit, which includes our build 
system for Mozilla, which builds and handles lots of edge cases with 
PyXPCOM, including a series of patches we have to build, fix or add 
functionality.  Komodo uses this build system and these patches, and has 
proven to be stable with PyXPCOM over a long period.

I wrote an email about it to the openkomodo-dev list a few days back, 
here it is:

http://lists.openkomodo.com/pipermail/openkomodo-dev/2008-January/000031.html

With just a little bit more work, the build system could probably build 
a redistributable XULRunner + PyXPCOM.  While we (ActiveState) wont have 
  time in the immediate future to do that work ourselves, I thought I'd 
mention it in case anyone was interested in digging in.

Regards,
Shane Caraveo
ActiveState

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