> I think if he really needs that much storage, he should just run a hard
> drive based FreeBSD system.
Exactly. That's what I meant by "significant hacking", making
m0n0wall work more like a normal FreeBSD install, using a normal hard
drive file system. m0n0wall was designed to boot from compact flash
and run from RAM, because of the write limitations of CF cards.
You could probably save yourself a lot of time by starting with a
project that's focused towards full hard drive installs, pfsense.
http://pfsense.org All the work of porting m0n0wall to a normal hard
drive filesystem is already done there.