When I was gathering pieces for my own ALIX box, I deviated from 
the Netgate script by buying some CF cards from Newegg.  Some
1GB cards of dubious quality run as low as $6.50.  I splurged
and spent around $9 for some faster 2GB cards.  "Faster" is
slightly important, size is not - damned near any CF card
will work, since OpenWRT is designed to run in a few
megabytes, and copies many of the files from CF to RAM
during boot.  The ALIX, with 256MB of RAM, has plenty.

Another cost savings measure for this project would be to
locate a large stash of high-quality small CF cards.  I
imagine there are professional photographers around town
with a whole bunch of used-once 128MB cards, abandoned
when they upgraded to larger and faster cards (you can
buy a 32GB card for $90 from Newegg).  The major problem
with older cards is that they are likely to have slow write
times.  Practically, waiting 60 seconds to write a few
megabytes to an older card, rather than 10 seconds, may be
justified by the monetary savings.  I will be running some
speed tests on various cards soon, so I can quantify this.

BTW, I am programming my cards with a "Digital Concepts" CF
reader/writer that I bought for $13 at a suburban Maryland
Radio Shack.  It Just Works with my Linux laptop - you Windows
guys may have more trouble :-).  I bought it with a third CF
card a 2GB Sandisk marked down from $90 to $30.  The R.S. 
website shows they are on sale for $20.  The point isn't that
you should buy from Radio Shack, but that you can get the
stuff to program these systems anywhere, and that the CF 
cards are not expensive enough to steal.

They might be swapped by crooks, though.  The usual saying
in computer security is that there is no data security without
physical security - if the bad guys can get at your hardware,
they can bypass all your security measures.  While I like the
idea of easy maintenance, the fact that a bad guy can quickly
swap a compromised CF in place of the PTP CF may create a
security hole.  I don't think we can stop a really clever 
bad guy, perhaps there are some software tricks we can add
to the CF cards to make superficial tampering more detectable
- perhaps digitally sign random portions of the CF image,
and querying the systems remotely.  Overall, I'm not going to
lose much sleep over this - in a world dominated by Windows,
where telephones are answered by gullible fools, there are
much easier targets.

Keith

-- 
Keith Lofstrom          [EMAIL PROTECTED]         Voice (503)-520-1993
KLIC --- Keith Lofstrom Integrated Circuits --- "Your Ideas in Silicon"
Design Contracting in Bipolar and CMOS - Analog, Digital, and Scan ICs

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