Making Your Own Router
networking I am kind of bad, but I am comfortably setting up routers, and thing like DDNS and OpenVPN servers.
I pretty good with linux. Not a master but I can do about anything as long as I have a lot of time and google. I managed a debian server running a samaba share, vpn server, plex media center, and a bunch of other stuff for my fraternity house.
I don't want Wifi, I want a great firewall with lots of features and a fancy web interface (I an comfortable with the terminal interfaces but I find a GUI easier for somethings) I would just need a to nic set up with one hooked up to the modem and the other hooked up to a 48 port switch.
I have an old system with some kind of AMD athon CPU and 4GB of DDR2. I also would be open to making a VM to run the firewall if that is possible.
I would prefer something that could do both, however I am comfortable with tinkering with a system.
Thanks for your help
Well then, I suggest you start with either pfSense or IPCop. This is mainly due to both of them being fairly noob friendly and relatively lightweight. There's a few important differences between the two however.
1. BSD or Linux
pfSense is based on FreeBSD. IPCop is based on Linux. Whilst you're not likely to notice this in normal operation this can cause issues when troubleshooting. *BSD also has worse hardware support in some cases.
2. Expandable vs. Lightweight
pfSense has a ton of add-on packages which do all sorts of wonderful things such as transparent proxy and intrusion prevention. A lot of these packages are also insanely resource hungry. IPCop has a traffic scanner/proxy add-on and that's pretty much it. Less packages used = less bloat.
pfSense can be fairly lightweight too if you don't install too many packages but the bloat in general has been creeping on it as time has gone by. IPCop (seeing as how it uses netfilter) can be expanded a lot too but that requires manual fucking around as opposed to just clicking a button.
IPCop can run on pretty much any hardware in its basic configuration (traffic scanning can be fairly resource intensive though). If your VM software supports Linux, there's a good chance it'll support IPCop. It'd also run just fine on your Athlon.
pfSense, as mentioned, is a bit more picky when it comes to hardware. A quick googling tells me that it ought to run in your VM software but whether or not your Athlon would run it depends highly on the packages added.

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