Slackfumasta said:
I can't believe that this is a thread about which router to buy, and nobody has mentioned Smoothwall yet!
I'm impressed. I say go for the Linksys WRT54G. Great router, good price.
quick, pull out a 486 and install smoothwall on it!
lol
but seriously, it depends on what you need to do. and in fact you asked for a router, not an alternative to a router.
smoothwall running on old rig is not cheap. initially, your cost might be zero. however as time progresses, old rig running smoothwall and/or other linux/unix variants use a whole lot more electricity than a pre-built router unit. by estimation, in the end of the first year the excess of electricity usage will offset the cost of your router. it is not difficult math, a router usually drains 60~120w, a pc drains 200~400w. you need a good reason to pay extra in power consumption. for a normal home network, there really is no valid reason for it. routers now days come with firmware that does everything you will ever need as a home user/avid gamer/small business professional.
second reason not to use smoothwall is that linux is highly configurable and there is a lot of room for userland configuration errors. It could lead to system wide security compromise. learning how to operate linux also cost extra time and effort.
third reason not to use smoothwall is that no matter how efficient software side of pc become, a pc will never be as efficient as an optomized hardware router for packet delivery. the key here is hardware optomizing. pcs don't have that.
only reason to use a pc to route is that you would like integrated QoS and don't want to spend more than 50 bucks for a router with that feature.