FreeGeek is a nonprofit community technology center and recylcler here in Portland. They came into a quantity of identical Unisys Pentium thin PC's and thought of our needs.
So JerrittCollord and AndrewWoods and IanSwift went about the process of handling/verifying hardware, cleaning, creating a standardized operating system image, etc. This is a typical what we call now "NoCat box" that performs NAT or other routing, DHCP, DNS and of course hosts the NoCatAuth captive portal software. The machines have one builtin NIC and MichaelCodanti donated a set of matching PCI nics that were installed in the one slot available.
There are 9 machines for use in nodes where PTP collectively is responsible for maintenance. Standardized for our ease of parts replacement, universality of platform knowledge, and general cuteness in size, etc. "Because someone gets a phone call"
Here's some notes describing what they are and how they were made, some tips for future similar efforts. Mostly system-level stuff, but also included the application-layer choices.
1) Use a journaling or otherwise resilient filesystem. You're retooling the hardware to be a routing appliance now, not a personal computer. Pull the plug while running, re-insert and 99% of the time it will come back on. We used ReiserFS.
2) Alter BIOS for our needs... halt on no errors (must run without keyboard), enable fast boot.
3) Test hardware extensively. Run memtest86 for RAM, a read/write badblocks scan on the HDD. (Ideally of course there would be solid-state storage instead of an HDD but cost constraints prevent that). Use no hardware that has any problems whatsoever.
4) Clean the hardware as much as possible... take it apart and dust with liquid air. Can be a problem for ventilation and cooling, also tends to muss open moving parts like floppy drives.
5) Use Debian. Intall dhcp, spong-client, bind9. Yes thinking about udhcpd and djbdns (dnscache). Drew's right below, spong is a hog; bind isn't so lightweight itself.
5.5) Install other packages, namely NoCatAuth.
6) have some StandardOperatingProcedures where the group decides on how stuff is done e.g. keep passwords written down in a couple places, use sudo, etc.
A couple other thoughts, not sure if you want them here. Install, Spong, NoCatAuth (MetaNet in the future?). Possibly worth investigating DNSMasq instead of Bind because it's much lighter weight, A nice DNS standardization would be for the gateway to always resolve as gateway.personaltelco.net (or somesuch) so that the SplashPage could refer to it for the status page in a standardized way. -- AdamShand
Ideally, something lighter than spong-client would be good, too. it's currently eating 12-14% of the memory on the spb node. -- AndrewWoods Right-o AdamShand, editing to reflect the image as-deployed. -- JerrittCollord
How do disassemble your clone box
- Unplug, unplug, unplug.
- Remove the three screws holding the case on.
- Slide the case off, Watch for strange lip thingy ..
- Remove your expansion card.
- Remove the Ethernet card and the ISA/ PCI connector.
- Remove the screw in the middle of the case that hold the front cover on.
- remove front panel by squeezing the expanders towards the middle. Make sure Power is OFF. See step 1. You will have to stick a something thin into the front near the power supply.... ZAP!
- pull the LED/reset SW cable connector.
- Remove all of the connectors from the DB connectors along the bottom of the BACK of the board. these would be the connectors on either side of the DB9 and DB25 connectors, DB15HD = VGA. There is one DB9 Female for IR connection, No need to remove that one.
- Unscrew the Four motherboard screws
- the mobo will tilt from the front away from the bottom revealing the proc and mem. If you follow the map printed on the bottom of the Mobo you could now replace the proc and memory.
- Remove memory anyway. I have never been able to put the board back together with the SIMM still in the board.