Well, I think the big issue with Astaro is the req. for 128 MB of RAM. I presonally think that's way to much for a firewall, and should be able to use 64. Now, they are sproting this as a solution for business, so if you're running squid along with the firewall, AND have quite a few connections...128MB might be feasible.
I think this should be lowered, but I guess they're not pandering to the home user too much. Personally I think 64-96MB might be enough. I'm running mine of a celreon 366 right now, and I've had no performance issues. I've monitored cpu activity for a while, and I barely see a ripple.
A P1/90 might not work out, but a celreon 233 might be ok. I'm pretty sure the 1.6HDD would work too, although the 4 GB I tried to use crapped on me. (I think it was a hardware issue though)
My advice, if you have the time, download it and give it a shot. Seems like you got a spare machine, so the only thing you'll lose is time. Personally, I don't think it'll be a waste of time for you.
jrjuiliano -
You're specifying the DNS server on each of the clients and the dns queries are not coming back correct? What do the packet filter logs say? Are the packets being dropped? What about other services, are they getting through? Are you sure NAT is working properly?
Let me know, I'll do my best to help!
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