pfSense Installation: A Scrounger’s Guide (Part Two)

pfSense installation

The computer I used as my new pfSense box.

In the last article, I discussed my project to turn an old computer into a pfSense firewall and set some guidelines for the project. In this article, I get to configuration of the pfSense box and pfSense installation.

pfSense Installation: Selecting the Hardware

As you recall from part one of this series, the base system requirements for a pfSense installation are:

  • Pentium II or better
  • 256 MB RAM
  • 1 GB of disk space for a standard installation; 512 MB of disk space for embedded systems

I immediately realized the system I used for m0n0wall would not make the grade (too slow and not enough memory). However, I had another old system that might work. I had a Pentium III (733 MHz) with 256 MB RAM. The motherboard for this system died a few months ago; I found a replacement on eBay (for $15), but the system has been running slow ever since. It seemed like an ideal candidate for conversion to a pfSense firewall.

Since I did not want to erase the contents of the original hard drive, I had to find another one to install into the system. I went through a box of old hard drives and found a Western Digital Caviar 22000. With 2 GB of disk space, it had more than enough space for pfSense. I swapped out the original hard drive with the Western Digital.

The next consideration was what network cards to install on the system. You need at least two NICs: one for the WAN and one for the LAN. Installing a third NIC allows you to have an OPT1 interface for a DMZ. Fortunately, there was already one Intel Pro 100 NIC in the computer, and I had a spare two. The Intel Pro 100s are PCI cards, and there are three PCI slots on this motherboard, so I used up all the available PCI slots, but that shouldn’t be a problem. If you need to buy NICs, the folks at recommend purchasing Intel cards (or systems with built-in Intel NICs) up to 1 Gbps. It would behoove you to by Intel PRO 1000s, at least for the LAN and OPT1 interfaces (on the WAN side, using a 100 Mbps NIc will not create a bottleneck for most residential broadband customers). A quick eBay search revealed than PRO 1000s are available for less than $10 (for both PCI and PCI-X interfaces). My Neoware thin client has a 1 Gbps 2-port NIC for the LAN and OPT1 interfaces, and a 100 Mbps NIC for the WAN interface. An upgrade to Intel PRO 1000s on this system is definitely something I will consider in the near future.

pfSense installation

The Compaq Deskpro motherboard recognizes the Samsung drive, so we can proceed.

With the hard drive and NICs installed, I was ready to move the computer over to the test bench and begin pfSense installation. After running setup to make sure the BIOS recognized the Western Digital drive, I put the pfSense CD in and booted the system. When prompted whether to boot pfSense from the CD or run the installer, I hit “I” and invoked the installer. This is where I had my first real setback: although the motherboard’s BIOS recognized the Caviar, pfSense did not, and I therefore could not install pfSense onto it. Fortunately, I had a Samsung sW0434A (total capacity: 4.3 GB) I could install (again courtesy of the box of old hard drives), so I powered down the system and replaced the Western Digital with the Samsung.

pfSense Installation: Options

Once the hard drive had been replaced, I was able to boot pfSense from the CD and begin pfSense installation. When the installer starts, you have a chance to change the video font, change the screenmap, change the keymap, or accept the settings. Since I had no reason to change the defaults, I chose “Accept These Settings“.

On the next screen, you have a choice between quick/easy install and custom install (there are also options to rescue config.xml and reboot). In most cases you can opt for the quick/easy install, but if you do not want to reformat the hard drive, or if you want to partition the hard drive onto which pfSense is installed, or specify a different hard drive geometry than what was detected by pfSense, you want to opt for the custom install. I just wanted to reformat the hard drive and install pfSense onto it, so I opted for “Quick/Easy Install“.

Next, the pfSense installer will give you a choice between installing the standard pfSense kernel, or the embedded kernel (which has no vGA console or keybaord available). I selected “Standard Kernel” and continued. After a few minutes, pfSense was installed, and I was prompted to reboot the system. With pfSense installation complete, I rebooted the system and was ready to run pfSense on this computer for the first time.

When pfSense runs for the first time, it will ask you to assign interfaces. I assigned fxp0 for the WAN and fxp1 for the LAN. [I opted to set up OPT1 from the web configurator, later on]. I also assigned the IP address for the LAN interface.

By now, pfSense installation and configuration was complete, and I had a fully functional pfSense box, but I hadn’t connected it to my network. That’s no fun, so in the next article, I will talk about what happened when I used the new system as my firewall.

External Links:

pfSense Hardware at

Intel PRO/1000 GT Desktop Adapter – Overview at

pfSense Hardware: A Scrounger’s Guide (Part One)

pfSense hardware

The Pentium P-233 that served as my m0n0wall firewall/router

When I started using pfSense as my primary firewall, it replaced my previous firewall solution: a Pentium P-233 running m0n0-wall. I eventually switched to a Neoware thin client running pfSense, which I ultimately upgraded to version 2.1.3. The Neoware thin client meets the pfSense hardware requirements for running pfSense on an embedded system, and offered pretty good value for the money – one would be hard-pressed to put together a system more cheaply than these pfSense appliances which has the same features and functionality. Yet while running pfSense from a thin client may be the best option for some users, if you have an old computer that meets the pfSense hardware requirements, this may be the better option. For that reason, I thought it would be an interesting exercise to see how easy (or how hard) it is to turn an old PC into a pfSense firewall.

Indeed, the system I used to run m0n0wall had been scrounged from spare parts. The case and power supply had come from an old barebones system I had bought in the late 1990s. The motherboard/CPU was one of a lot of three I had bought on eBay a few years later, and the CD-ROM was from a group of spare CD-ROM drives I had, as was the floppy drive. I only had 32 MB of RAM initially. I found that with only 32 MB of RAM installed, m0n0wall’s web-based configurator would eventually crash (although the firewall itself would continue to function). I found another 32 MB of RAM on eBay for a few dollars, and my system was complete. The NICs had also been taken from old computers, although I eventually bought a lot of 10 Intel Pro 100 cards for $35. As underpowered as this system might seem, it served ably as my firewall for several years. Thus, I began to wonder if I had any old hardware that could run pfSense, and decided that for my next mini-project, I would take an old computer and turn it into a serviceable pfSense router.

pfSense Hardware: The Guidelines

For this project, I set out some basic guidelines:

  1. The hardware had to meet the general requirements for pfSense hardware. These requirements are listed on the official pfSense web site. For any installation, a Pentium II or better with at least 256 MB of RAM is recommended. For hard drive installations, a 1 GB hard drive is required (and a CD-ROM drive for installation).
  2. When possible, I would scrounge from existing resources to put together a system that would serve as my new pfSense box. If necessary, I would buy new hardware, but only as a last resort.
  3. I was not completely sure what the final system would have installed on it, but I knew at a minimum I wanted to have the most recent pfSense version (2.1.3 at this writing), and probably Squid, SquidGuard, and probably some other packages.
  4. To the fullest extent possible, I would document the process, so I would have a record of what worked (and what didn’t work).

These guidelines should provide a rough road map for this project. In the next article, I will cover the selection of hardware, putting together my pfSense box, and installing pfSense onto it.

External Links:

Hardware for pfSense at – pfSense hardware requirements guide

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