I would consider the Linux Router Project. LRP is small enough to fit on a single 1.44MB floppy disk, and is said to make building and maintaining routers next to trivial. A Pentium class system with 16 MB of RAM. Check out these links: http://leaf.blkmtn.org/LRP2.9.8-HowTo.html http://lrp.c0wz.com/ http://www.linuxrouter.org/