Building a Perfect pfSense Router under $25 with HP T630 Thin Client + 2.5Gb Intel NIC

This guide details how to build a cost-effective, energy-efficient pfSense router/firewall using an HP T630 Thin Client. The total build cost is under $25, making it an excellent option for home networking enthusiasts.

For a better experience, follow this guide on my website.

Why This Build?

Advantages

• Cost-Effective: Complete build under $25
• Energy Efficient: Low power consumption (12-28W)
• Silent Operation: Fanless design
• Performance: AES-NI support for VPN capabilities
• Expandability: 2.5GB LAN for future-proofing
• Compact: Small form factor

Use Cases

• Home network routing
• Network segmentation (Home/Guest/IoT)
• Basic firewall implementation
• VPN server capabilities

Hardware Requirements

Base System: HP T630 Thin Client

• CPU: AMD GX-420GI (with AES-NI support)
• Power Consumption: 12W idle, 28W under load
• Cooling: Passive (fanless)
• Integrated NIC: 1 Gigabit Ethernet
• Expansion: M.2 E A Key slot
• Cost: ~$15 (eBay, brand new)

For detailed specifications, visit Parky Towers T630 Documentation

Additional Network Interface

• Model: Realtek RTL8125B
• Speed: 2.5 Gigabit Ethernet
• Form Factor: M.2 2230 (E A Key)
• Cost: ~$7-9 (AliExpress Link)

Hardware Assembly

1. NIC Installation

   • Remove the detachable VGA port from the thin client
   • Install the M.2 NIC in the vacated slot
   • No additional modifications required

2. Network Configuration

   • Integrated 1GB NIC → WAN connection
   • RTL8125B 2.5GB NIC → LAN connection

Software Installation

Prerequisites

• pfSense ISO
• Etcher or similar USB writing tool
• USB drive (minimum 8GB)

Installation Steps

1. Create Installation Media

   • Download pfSense installation image
   • Write image to USB drive using Etcher
   • Boot T630 from USB drive

2. Initial Setup

   • Complete basic pfSense installation
   • Note: RTL8125B NIC won't be detected initially
   • Configure WAN interface using integrated NIC

3. RTL8125B Driver Installation

   • Access pfSense console (Option 8 for shell)
   • Install Realtek driver:

   pkg add net/realtek-re-kmod

   • Configure driver autoload by adding to /boot/loader.conf:

   if_re_load="YES"
   if_re_name="/boot/modules/if_re.ko"

   • Reboot system
   • Assign interfaces (Option 1 in console menu)

Performance Considerations

This build is suitable for:

• Internet connections up to 1Gbps
• Multiple VLANs
• Basic to moderate VPN usage
• Small to medium home networks

Additional Resources

• pfSense Documentation
• HP T630 Technical Details
• RTL8125B Compatibility Reference

Conclusion

This build provides an excellent balance of cost, performance, and efficiency for home networking needs. The HP T630 with added RTL8125B NIC creates a capable pfSense router suitable for most home networking scenarios, all while maintaining a budget under $25.