I've toyed with doing this a few times as it would give me a more versatile gateway edge device than my current router. My D-Link DIR-615 is performing quite well and if I really wanted to it'd be no big deal to flash it to DD-WRT or another firmware. I just like to tinker with my network and was thinking of converting my Amahi box into a ClearOS box and possibly make my network performance even better, or perhaps it'll stay the same. I was thinking of throwing in along with another gigabit network card (has one built in to the motherboard) a pair of wireless network cards (one 802.11 G and one 802.11 N) so that B/G devices on my N network won't affect the wireless N network's device speeds. There are some other nice perks that I see in possibly using this OS. So how many other folks setup a PC this way or do you all just use a router with custom flashed firmware?