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yeah, I've been there. It's where I found the LFS howto. Unfortunately, the mirror nearest me (and also with the fastest connection) doesn't have functioning download links. Oh well, after I finish some homework I am going to finish reading the HowTos already mentioned.
Also, regarding X running in 4MB. MasterC is right, I was using the laptop in question mostly for an X client only (actually, X server if you want to get technical; the client is the one running the X software, while the server is the one displaying it); however, I did have standalone X and X apps running in only 4MB. With that little, it is extraordinarily sluggish, and thrashes the swapfile, but I am confident that the setup I have would run more than comfortably in 16MB. muLinux comes with X and three window managers, which worked decently on my other 16MB laptop. And keep in mind those are both 486es! For the 4MB one, I was even using the most recent version of Slackware, with its largish 2.4.20 kernel. Using an older kernel and paring down memory usage even further would make it work even better. This story mentions one guy who got X plus Blackbox running in under 800K of resident memory (though he had 32MB to work with).
Anyway, I digress. I just wanted to make the point that X can be perfectly happy with only 16MB RAM. As long as you're not running 20 apps at once, it should be fine. But all this is irrelevant if you don't plan on running X
Ok, I guess the first thing is to decide what you want to go with, and I'd personally say, go for an LFS instead of Diskless on the box itself. You can certainly have plenty of diskless/NFS'd mounts on it, but the experience (IMHO) would be best if LFS was on the firewall, and then for most other things (if you desire X) you run diskless/NFS setups. Here's the diskless How-To: http://tldp.org/HOWTO/Diskless-HOWTO.html
Anyway, assuming we go LFS on the box, here's how I'd go about it:
Throw in your Gentoo CD, get to the prompt, change your root pass, then start up lynx:
lynx linuxfromscratch.org
And start. Instead of untarring a stage tarball into the filesystem though, you'll take off with LFS from there. You can also/instead just boot up, don't use any of the Gentoo ideas, and just start from ground zero with LFS (probably more beneficial). Then, when it's all done, you should have a working/bootable LFS system, and you can begin with your Firewall needs. No need to go BLFS, other than to get a few text editors, maybe some of the bare minimum other things running as well, DHCP (should you need it) and then begin with IPTables. If you are going to be using a tool, I suggest a look at shorewall OR, since it would fit, you could put Apache on that same box, and setup a remote admin client over a secure web browser. The world is your oyster at that point.
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