I've wanted to setup a serious linux-based firewall for my home network for some time now, and I finally got around to it yesterday.
There are TON of linux router distros out there, but instead of spending 8 hours picking & choosing, comparing & contrasting, nitpicking & debating, I asked someone else ;). Two buddies of mine have a similar setup at their homes: one uses Smooth Wall; one uses IPCop. I arbitrarily chose Smooth Wall (after actually setting it up, though, I think IPCop would have been a better choice--c'est la vie.
The installation is supposed to be quite painless, and it was--for the most part. The documentation and install process was intuitive and easy to follow, but it didn't work OOTB. I probably only had so much difficulty because of hardware issues (fried NICs?) which is by no means Smooth Wall's fault. Nevertheless, it took ~5 hours of bang-your-head-against-the-table troubleshooting 'till I could finally unhook the monitor & keyboard, shove it in a corner, and get some sleep.
I was also disappointed with two things that didn't work as I had expected OOTB:
DHCP DNS VPN Michael Altfield
Hi, I’m Michael Altfield. I write articles about opsec, privacy, and
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