Dean,
I agree with you that social engineering is a valid attack vector (and often the most effective).
However, I think the initial comments (at the very least my own, but I thought others felt the same way) was that SE was something that wasn't enjoyed. For myself this is largely a confidence issue, I'm not a 'people person' therefore trying to convince someone I'm something I'm not is something I don't relish.
I do enjoy the non-interactive, techinical social engineering techniques however and have used dummy sites and spear-phising as an alternative. Following this thread I'm looking forward to testing what happens when I 'lose' a USB stick, thanks for the advice you gave njemjy regarding msfpayload as this should come in useful in this regard.
From those that are skilled at/enjoy social engineering, do you have any advice on how to best introduce yourself into a client's environment? I can't imagine anyone believing my cover stories, would you trust a nervous sweating bloke with your server room?

Maybe I'm strange but I quite enjoy the SE side. Maybe it's because I come from a service background and enjoy meeting the customers.
Maybe it's because I blend well and I don't believe I look like your stereotypical computer geek or computer security geek - that makes it easier.
But the general comments here are correct - SE is probably the easiest way to get into a system or at least to get close enough to get into a system!
As for getting into a client site, don't aim for the server room. Aim for other parts of the organisation and include the server room if necessary. If you can get access to a live network port, you're 90% there anyway.
Sometimes, using a toilet just off reception can get you the access you need - you might be suprised the route ethernet cables take - access is often just a ceiling tile away...