Router project update

Extension on http://davidgrundmann.blogspot.com/2009/03/router-project.html

So I got the router up an running but not without flaws. Apparently there is a serious worm going around targeting openwrt project based routers. While the security risk is limited to bad passwords and open ports I decided not to take the chance so it's not going to be a gateway.
My main server is now off and sitting quietly while I have 2 routers up an running for our network. One is a wireless router that hosts the gateway (generic wifi router) and the other is the print server (WGT6534u).
The print server portion of this is a bit tricky, I'm lucky that my other printer has a network port on it (HPCL3600N)... If it didn't then I would potentially get a confusing mixture of devices if the router reboots. The mapping to /dev/lp[0-9] is dymaic and the print server (p910nd) points to each dev directly. I could make a dynamic script to scope the device ID and bind it accordingly but I didn't really need to since only 1 port is used.
The p910nd driver for the print server is interesting... typically I would use cups but the wiki for openwrt used p910nd which is a non buffering version of a server (basically it just pushes the raw data directly to the printer where cups spools it locally then prints). The bad side to this is that if the printer is off the job will be lost right away where cups could store it till the printer is back on.
Since my requirements became less by not using as a direct gateway I removed the usb key and loaded the small set of utils on ROM (ssh/p910nd/usb-drivers). Now I have an extra key :) The router now boots slightly faster than before (maybe 1-2 seconds) because it doesn't need to change the root system to the usb key and that the usb port is somewhat slow (despite being usb2)

Since my goal was to reduce power, the 2 routers (gateway + print) consume 12w combined without many compromises. This is 10x less and with $/kwH around $0.17 I will save quite a bit!

Now the real test: will they last? The reason why I used a server (PC/linux) was that I had 3 routers crash constantly or be flaky and burn up (not flames, though that would be cool)! I got tired of rebooting them every day so I built one. I guess if these routers dont work I'll buy an n270 atom chip + mobo and build my system that way :)

So what to do with the 2nd WGT634u? Hmm, maybe a security cam to take place of a $200+ one?

Router Project

So after getting a bit annoyed at our electric bill being the same month after month I decided to get back onto building a mini smart router. Currently I use a P4 computer (under clocked) that hosts files, is a web server, print server and a quality of service for internet amongst other things. Most off-the-shelf router don't even come close except for one particular model.. a netgear wgt634u which is no longer made (shame).

So why use an out of date router? I had it and wanted to make the best of it, besides I have 2 so if i get one working then i can use the other for those network cameras :) The best part is that the 634u is a mips processor with 8mb of flash, usb, multiple network ports and wireless all in a 5w package.
*Here's an image of a semi-modified of the 634u.

I got this at CompUSA refurbished for cheap! The reason for refurb (my guess): overheating, hence the extra heatsinks. The black one is the processor (broadcom mips 200mhz) and is on with epoxy. The others use thermal tape is is of my doing. With an IR gun the heatsink gets up to 60C quickly.. a bit more than I appreciate so an addition of a small fan should suffice.

I found a nice initial disto: http://wiki.openwrt.org/OpenWrtDocs/Hardware/Netgear/WGT634U that is proving most useful. I had to buy some components to build a serial comunication interface and get a usb adaptor.
The chip is a SP232CP. When connected I'm able to talk with the router and load linux on it via some very old connumication ideas (tftp). So far I've been able to load usb drivers for the thumb drive. I found some extra commands to swap what the root is so I can use the thumb drive instead of flash which gives me much more space to load stuff :) Once I got this down (and revisited how to modify the rd.d) I started to load openssh and cups. I plan on more but need to ensure this minimum mount of tools works before going further.

Once I'm done I will cut my server energy usage by 24x (old server uses about 120watts)

If all else fails I'll just get an Intel Atom server for $70 which is about the same power consumption :) That way I can easily compile things on my own and use gentoo which is my preferred choice of linux.