@alixman:
You are very helpful. So if I bought the DC7800 you listed, what upgrades would you do? SSD for sure for squid/snort, what else?
Well, I'd put in more RAM, for sure. I mean, 1GB is great for normal routing, but if you're doing extended features, you'll want more. They can cheaply take 4GB, 8GB isn't too expensive.
I would probably get a good dual port PCI-Express Intel Gb NIC, it'll fit in your PC-Express x16 slot (you don't need a video card in a router, the features supplied by the onboard/integrated GPU are already overkill.) It has an integrated Intel Gb NIC already.
If you need something physically smaller, the Small Form Factor versions of the same can be slightly cheaper, but they'll need low profile cards.
Past that, unless you've got some serious internet access and/or plan on doing some crazy stuff, upgrades would probably be just for the sake of upgrading, not noticeable performance. I mean, this hardware should be able to get close to saturating Gb internet with pure routing; VPN somewhere between 50Mb and 100Mb (+/- probably 20Mb depending on the type of VPN.) I'm not sure what dedicated crypto cards would do for you, though.