I happen to be one of those guys who favors clean installs whenever possible (too many years using Windows, I guess…), so doing that on so important a piece of equipment as a router is no big deal - I was just curious about other user's upgrade stories.
As to the config files, yeah, I should've saved those... I'll do that next time, and report back.
I remember though that one of those upgrades (a MultiWAN setup on an old Intel 845 mobo, with 512MB RAM and Intel, SiS and Realtek NIC's - yes, I'm that brave! :D) ended in a loop assigning interfaces - meaning, the "assign interfaces" console routine kicked up after the upgrade, but no matter how many times I did the (re)assignment, it always cycled back to the same screen; unfortunately, I had some urgency in restoring Internet access, so I just reinstalled on top of the botched upgrade (using version 2.0b5, and manually recreating the configuration) - it's been working flawlessly ever since.
Thanks - for the reply, and for giving us pfSense!
Marcello