DIY pfSense Rackmount Router Build Log - Part 1

This video documents the early phase of a DIY pfSense rackmount router build, focusing on planning, hardware selection, and the initial mechanical challenges of fitting a compact 1U form factor. The host begins by outlining the goal of creating a high-performance pfSense box and sets up the project within a Cooler Master MasterCase 5, emphasizing modularity and space constraints. He walks through the hardware lineup, including a low-power Intel Xeon E3 1260L, a Kingm Kingston server board, a special low-profile memory module, and a 1U rackmount case from Norco. A key theme is how form factor constraints drive creative solutions, such as fabricating a custom IO shield and trimming a back plate to accommodate the cooler and ports. The setup also includes a sideways-mounted i340T4 quad-port NIC, an SSD, and a 1U redundant power supply, with attention given to airflow and cable management to preserve cooling. Throughout, the host tests fitment and clearance, noting potential interference between components and the need to adapt standard parts for the 1U footprint. The section closes with a preview of ongoing trials, including a planned Windows-based testing phase to evaluate cooling performance before finalizing the pfSense build.

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