This page provides a description, suitable for following along at home, of how we have been creating the firmware image for the AlixCab and WgtCab devices that we've been working on.
The AlixCab and WgtCab are named after the CloneArmyBox and subsequent NewCloneArmyBox (or NuCab) they are meant to replace. These predecessors were based on recycled PCs that we obtained for free and, running Debian GNU/Linux, repurposed as routers/gateway devices for our network installations. The AlixCab and WgtCab are based on the Alix single-board computer (from PcEngines.ch) and the Netgear WGT634U, respectively. PersonalTelco is (as of late June 2009) part way through a purchase of 30 Alix boards. We already own or have deployed a number of Netgear WGT634Us. PersonalTelco has some Soekris board (typically as MetrixKits) deployed about as well, running various firmware. It is notable that the same firmware (or slight permutations) as described here can also run on the Soekris devices.
The respective firmware images for the AlixCab and WgtCab are both based on OpenWrt.
(MORE DETAIL TO FOLLOW SHORTLY)