@wifiguy:
What type of throughput/routing should a box like this be able to handle? Close to a full Gig shouldn't it?
Depends on the actual CPUs installed and what packages, traffic shaping, etc. you use.
The reason people with i3 and i5 CPUs can get close to wire-speed on Gbe is their extremely high clock speed. For simple routing+firewall performance, a brand new box with an i3-2130 would crush the R900 box you probably spent $20K on, an i5 has even more capacity because of Turbo Boost and the fact that the workload is largely single-threaded.
EDIT: What is your current hardware? What, exactly, do you plan to use this pfSense box for other than firewall duties?