I know this topic is quite old, but I'd like to add my own & successful try to build a low-cost pfSense router.
In detail it was just projected to be an upgrade to an old D-Link 524 in a mechatronics lab envoirment, wit just a few features - like static IP assignment of clients via their MAC adress & MAC-Whitelisting as well as blocking access to the internet from or to the lab equipment [including several Siemens Siematic PLCs, a Kubota robot arm, Several printers and a professional 3D Printer], but not the PCs.
The D-Link was used as an AP instead, this saving the cost of buying a wifi card that isn't faster anyway...
[I hope 802.11ac support and drivers for the Intel 7260ac will soon come!].
I used an ASRock J1900M Mainboard [€ 40],
an LC-Power 1400 Case w/ 250W PSU [€ 40],
3 Realtek 811x NICs with PCIe x1 [€ 5 each]
as well as a Corsair ValueRAM 2x 2GB DDR3-1333 Kit [€ 30]
and a Transcend 32GB 2,5" SSD [€ 20]
Which totaled around € 145 in parts and € 150 with shipping.
Since it neither needed VPN or any crypto handling besides it's HTTPS web interface, performance is sufficient.
On the WAN side, this unit just goes straight into a Cable CPE with roughly 150M/10M, and it can fully saturate that [before the D-Link capped it with it's 100M ports...
This setup was easy to deploy and fully satisfied the customer's needs, as it was just the needed and reasonable priced upgrade to a customer/SoHo router and while being cheaper than the famous Fritz!Box routers, it had significantly more features and didn't have arbitrary and artificial limitations [like MAC-Whitelisting only on the Wireless interface and limited to 25 devices like the D-Link].
Sadly, with some of those cheap ASRock boards being in low supply, espechally the QC5000M [same board, but with an AMD A4-5000, thus having AES-Ni], the few offers on Amazon ramp up prices to 300% or more - at least in Germany.
But I'm pretty shure some Celeron J4xxx or J5xxx as well as potentially upcoming, low-end Ryzen-based SoCs will fill the gap without getting too pricy.