Thanks for all the advice. Adding a VLAN to the LAN interface would be the way forward, but every time will do it, it kills the firewalls built in openvpn access, and we have to send someone to the datacerter, restore a config, reboot it then it works.
Agreed, multihoming is not the answer.
So we thought of another solution: to connect the spare interface (opt-2) to a separate (VLANed) network. We have done this, but the machine on this new network (anothe pfsense box) cant even ping the main pfsense box. What magic has to be done in pfsense to make opt-2 behave like the LAN, not a WAN? When you go into the LAN interface settings in pfsense, you can just set the ip (and optionally bridge).
When you go into opt-2, you have a lot of WAN type settings which I dont think we need. I set the address to static, bridge:none, ip is 10.10.10.1/24.
Now I connect another pfsense box on this network (i.e. connected to the same switch, with both ports in the same VLAN), give it 10.10.10.2 for its WAN, try and ping 10.10.10.1 and it cant see it. Do I have to bridge anything?
the reason there is two pfsense boxes, is that the first one is the datacenter main perimiter box, and the second one is a staging environment ment to act the same as the production environment, so we want to be able to play with a staging copy of the production fws etc).
Any ideas?