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pfsense is probably the best distro around, unfortunately no distro can teach your want you need to know ;-)
You can give m0n0wall a spin which is a "baremetal" version of pfsense (pfsense kinda derived from m0n0wall).
//Danne
FWIW, the WNDR4000 isn't really sn updated version of the WNDR3700 since its a completely different platform. The WNDR3800 is on the other hand an updated version of WNDR3700 (v1 and v2).
I would for sure look at a TP-Link TL-WDR4300 which is a refresh of the WNDR3800 hardware (less flash memory...
Instead of FreeNAS I'd recommend you to use the "new" version running FreeBSD 9. Haven't used FreeNAS or NAS4Free myself though.
http://www.nas4free.org/index.php/nas4free-home/
//Danne
Looking at the hardware specs I'd say that you're much better off getting a recent Ralink or Atheros platform depending if you're fine with vendor supplied firmware or 3rd party.
http://www.hydrogenaudio.org/forums/index.php?showtopic=58720 (found here) and v2 seems to have similar hardware...
Wireless works very good, Ath9k works by far best in Linux so I'm not sure where you're reading. All except the TP-Link (yet I'd suppose) also work with OpenWRT :-)
http://wiki.openwrt.org/toh/buffalo/wzr-hp-ag300h
http://wiki.openwrt.org/toh/netgear/wndr3800...
This sounds more like a plain configuration issue more than real performance issue and reading a bit more.... http://forums.untangle.com/networking/20335-10000-maximum-tcp-sessions.html
This is to keep performance with reasonable limits, pf doesn't do layer 7 filtering like iptables does at...
Sounds extremely slow for a plain firewall and given those says I'd say that you'd need something more powerful. If you're just looking for a firewall m0n0wall (requires less processing power than pfsense) would be something worth looking at otherwise pfsense. Have in mind that a plain mips...
@ YeOldeStonecat
Intels works good (62XX/63XX) but I've found Atheros (9XXX-series) to have better coverage (range/sensitivity) than Intel in general. Realtek and Ralink are just hopeless in general :/
@ dashpuppy
Tss... same same but different :-D
//Danne
http://www.google.com/products/catalog?q=zyxel+nsa-325&hl=en&prmd=imvns&bav=on.2,or.r_gc.r_pw.r_qf.,cf.osb&biw=1920&bih=1096&um=1&ie=UTF-8&tbm=shop&cid=13483233783443858787&sa=X&ei=6rzRT8-fEdLR4QTQ5fWuAw&ved=0CHMQ8wIwAA
Zyxel NSA-325 looks like a very good deal especially having the hardware in...
@ dashputty
Like I said before, the TP-LInk TL-WR842ND would do that just fine. I don't see why the E3000 would qualify and the TL-WR842ND wouldn't as its faster...
I honestly think this boils down to more $$$ == better just for the sake of it sometimes...
//Danne