I have not used it, but as IPCOP handles all the NAT, DHCP and DNS proxy roles of a router, why not just use a switch? In order to use it as with a Linksys router you have to place the router in router, not Gateway, mode, disable DHCP, set the router to obtain an address automatically, and plug in a cable from the IPCOP device to the router's normal LAN ports.
Lets look at this logicly. You have a software firewall application in which you have defined as seen above 3 different subnets: 192.168.1.x, 192.168.2.x, and 192.168.3.x.
Your ISP gives you 5 different static IPs.
You have a modem that accepts only 1 external IP address for your ADSL connection, and it too offers NAT, and DHCP.
You have a Linksys router that is offering NAT and DHCP services, and it offers only 1 WAN or external side port.
The only reason that your setup worked at all as first described in your post was that the Red Zone definition and Router ports fell within the DHCP scope of the modem. Once you placed non-private IP definitions for Red Zone and router Gateway, the whole house of cards collapsed.
It matters little whether your ISP gave you five IPs or a hundred, you need a different modem (bridge modem) or the ability in firmware to setup your modem as a bridge.
You then need a switch. So, modem -->switch
You then need at least 4 nics in the IPCOP machine, two nics for multi-homing from the switch, and 2 to provide DHCP addressing and multiple Gateway services for the LAN side.
You then need another switch to connect the IPCOP machine to your LAN clients.
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