Skip to content

Make something from an old Router or Modem

Energy needed to make [e.g., 150 MJ per unit]
Critical earth materials [e.g., 5g cobalt, 2g lithium]
Energy needed to disassemble [e.g., 10 kWh for full dismantle]
Energy to procure materials [e.g., 50 MJ for CRMs procurement]
Total supply chain emissions

Comparison of the Routers

Custom firmware like OpenWRT or DD-WRT can unlock more features on supported router models, but compatibility varies—always check for your exact hardware revision to avoid bricking.

Router ModelTypeWi-Fi StandardCPU / RAM / FlashPorts / FeaturesCustom Firmware Support
Buffalo WBMR-HP-GNV2ADSL2+ modem router802.11b/g/n (150 Mbps single-band)Lantiq XWAY VRX208 / ~32MB RAM / 8MB flash4x Ethernet, 1x ADSL, USB 2.0Partial (source code available; possible OpenWRT/DD-WRT hacks, but not officially listed)
Technicolor CGA2121DOCSIS 3.0 cable modem router with VoIP802.11n/ac dual-band (300 Mbps per band)Broadcom BCM3384ZU (1.5GHz dual-core) / 256MB RAM / 128MB flash4x Gigabit Ethernet, 2x phone, coax, USB 2.0Limited (hacking tools exist for unlocking features, but ISP-locked; no easy OpenWRT)
Zyxel VMG3925-B10BVDSL2/ADSL2+ gateway802.11ac/n dual-band (up to 1.3 Gbps)Broadcom BCM63168 (400MHz dual-core) / 128MB RAM / 128MB flash4x Gigabit Ethernet, 1x DSL, USB 2.0Strong (OpenWRT build guides available; firmware source on GitHub)
Zyxel NBG-417NBasic wireless router802.11b/g/n (150 Mbps single-band)Realtek RTL8196C / 16MB RAM / 4MB flash4x Ethernet, no modemModerate (similar to supported models; OpenWRT possible on variants like NBG-419)

In summary, the Zyxel VMG3925-B10B stands out for better Wi-Fi speeds and easier custom firmware tweaks, while the NBG-417N is the simplest (and most limited). The Buffalo and Technicolor have modem capabilities, making them suited for ISP-specific repurposes, but all can be hacked for geeky projects with varying effort.

Geeky Projects: Breathing New Life into Old Routers

Old routers like the Buffalo WBMR-HP-GNV2, Technicolor CGA2121, Zyxel VMG3925-B10B, and Zyxel NBG-417N gather dust in drawers, but with a bit of tinkering, they transform into custom gadgets for home labs, IoT experiments, or retro setups. These devices run embedded Linux under the hood, so flashing open-source firmware unlocks their potential.

We’ll use tools like a computer, USB drives, screwdrivers, and optional cheap components (under $10, like jumper wires or resistors from online stores). Disassembling is involved in tougher projects, but safety first: unplug everything and discharge static.

Easy Project 1: Wi-Fi Range Extender (All Models)

Turn any of these into a signal booster for spotty home Wi-Fi, no disassembly needed. Ideal for the single-band Buffalo or NBG-417N, but dual-band models like the VMG3925-B10B or CGA2121 shine here.

What You’ll Make: A dedicated repeater that extends your main router’s network to dead zones.

Steps:

  1. Check compatibility and download OpenWRT (or DD-WRT if supported) from openwrt.org or dd-wrt.com. For example, search for your model in their device tables—VMG3925-B10B has direct builds.
  2. Connect the router to your PC via Ethernet. Access its web interface (usually 192.168.1.1; default credentials like admin/admin).
  3. Flash the firmware: Upload the .bin file via the router’s upgrade page. Wait 5-10 minutes; don’t interrupt power.
  4. Reboot and access OpenWRT’s interface (192.168.1.1, user root). Set it to “client” mode under Network > Interfaces > Add new (scan for your main Wi-Fi, enter password).
  5. Position the router in a weak-signal area. Test by pinging from a device—it should now connect seamlessly.

Pairing Idea: Hook it to an old laptop via Ethernet for a portable hotspot setup.

Easy Project 2: Basic NAS File Server (Models with USB: Buffalo, Technicolor, Zyxel VMG3925-B10B)

Repurpose as a low-power network storage device for sharing files across devices. Skip the NBG-417N (no USB).

What You’ll Make: A mini NAS for backups or media, using a cheap USB drive.

Steps:

  1. Flash OpenWRT as in Project 1.
  2. Plug in a formatted USB drive (FAT32 or ext4).
  3. In OpenWRT interface: Install packages via System > Software (search for “luci-app-samba4” for file sharing).
  4. Configure Samba: Go to Services > NAS > Samba, enable it, set share name (e.g., “OldRouterNAS”), and allow guest access.
  5. Access from any PC: Map the network drive (\192.168.1.1\share). Drop files and stream media.

Pairing Idea: Connect to an old Raspberry Pi (via Ethernet) running Plex software for a full media server—Pi handles transcoding, router shares storage.

Hard Project 3: Custom IoT Sensor Hub (Zyxel VMG3925-B10B or Technicolor CGA2121; Disassembly Required)

Disassemble for GPIO pins and turn into a smart home controller for sensors. These have beefier CPUs for this.

What You’ll Make: A hub that monitors temperature/humidity and alerts via email, using cheap sensors ($5 DHT22 from Amazon).

Steps:

  1. Flash OpenWRT. Open the router case (unscrew 4-6 screws, pry gently with a flathead).
  2. Identify GPIO pins on the board (use online pinouts for Broadcom chips—search “BCM63168 GPIO” or similar). Solder jumper wires to exposed pads (e.g., pins 4-6 for data).
  3. Connect sensor: Wire DHT22 to GPIO (data to pin 4, VCC to 3.3V, GND to ground). Use a 10k resistor if needed.
  4. Install packages in OpenWRT: “kmod-gpio-custom” and “python3” via opkg.
  5. Write a script: SSH into router (ssh root@192.168.1.1), create /root/sensor.py with Python code to read sensor (use Adafruit library if installable). Cron it to run every minute: “*/1 * * * * python /root/sensor.py > /log.txt”.
  6. Set up alerts: Install “msmtp” package, configure email relay to notify on thresholds.

Pairing Idea: Link to an old Xbox 360 (via Ethernet) modded with XBMC—use the hub to trigger game room lights based on sensor data.

Hard Project 4: Isolated VPN Gateway with Parts Harvest (All Models; Full Disassembly)

Break down routers for components and build a secure VPN box for privacy experiments.

What You’ll Make: A Frankenstein VPN router using antennas from one, board from another, for anonymous browsing.

Steps:

  1. Disassemble all: Remove screws, detach antennas (unsolder if needed), extract main boards. Harvest Wi-Fi antennas from Buffalo/NBG-417N for better range.
  2. Pick a base (e.g., VMG3925-B10B board). Solder harvested antennas to its Wi-Fi chip pads (use flux and a $10 soldering iron; match impedances roughly).
  3. Flash OpenWRT on the base. Install “openvpn” package.
  4. Configure VPN: Generate keys on your PC (openvpn –genkey), upload to router. Edit /etc/config/openvpn: Set server mode, port 1194, push routes.
  5. Power via external 12V adapter (harvest from one router). Test by connecting devices—traffic routes through VPN.
  6. For extras: Pair boards in parallel (Ethernet bridge) for redundancy.

Pairing Idea: Connect to an old laptop (as compute node) and Raspberry Pi (for monitoring)—create a mini cluster where the VPN protects Pi’s IoT traffic and laptop runs simulations.

Tags: