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The Making of a Beast: WRT54G Mods, Part One

The Making of a Beast: WRT54G Mods, Part One

The WRT54G is one the most versatile routers; having a cheap price and a bunch of alternative firmware for it.  One can find them at swap meets and second hand store all over the US.  The can be used as access points, routers, bridges, repeaters and sometimes as all the above.  This instructable will not go into the firmware aspect of the router, nor will it go into antenna desgin; the instructions I provide are a quick and dirty way to create a beast out of your WRT54G.

My entire want is for my WRTs was to be used as a long range repeater.  I also wanted to make it Power-Over-Ethernet (POE) so I could put it some where electricity was hard to acquire.  CAT5 cabling allows for 48v and 350mA over two of the four pairs, totaling in around 16w of power.  The WRT54G use a 12v 500mA adapter, so at peak operating it is using 6w of power.  By no means is this PoE standards ( please red up on PoE step 9); however, the router will be operating with PoE.  Since in my case I will not be using any cross-over cabling I will eliminate a diode bridge.  When we arrive at that part I will explain the purpose and function so one can decide if they need diodes in their project.  This will allow me to network this out 100meters from my house and bridge and repeat another signal as well.

This instructable is crude and full of no-nos, so take it as a lesson in how you can modify your router by voiding the warranty.  This was a quick solution to a problem I was facing and I took pictures while doing it.  There are better ways, but this worked :)

Part Two is here
 
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Step 1Tearing it down!!

Tearing it down!!
First let me state the following: AS SOON AS YOU BREAK THE WARRANTY LABEL YOU ARE ON YOUR OWN.  EVERYTHING AND/OR ANYTHING THAT HAPPENS FROM THAT POINT ON IS YOUR RESPONSIBILITY.

The v8+ opens up very simply.  Two small tabs are really the only thing holding it together.  Take the feet off and use a small screwdriver and pop the front off.  After that it prety much falls apart.  Bring the top back;  two screws in the center of the board need to be taken out.

Now lets get rid of those awful antennas. 
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42 comments
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Apr 11, 2012. 5:45 PMOroka says:
OMG YES, this is exactly what I needed. I am setting up a network between me and my fathers house about 200m away and am going to use 2 wrt54g (a v1 and v8) and 2-3 25dbi yagi antenna.

I dont plan on modifying my precious v1, but the v8... I dont mind hacking up :D I might just get another v8 just for this. I have to add some TNC male connectors for this, got them on order from china :D

I probably wont attempt the poe just yet, but maybe if I get a second v8 that it will be fine if I fry... :D
Oct 12, 2011. 9:03 AMhwally says:
Great build. Gave me some ideas. I want to add a fan to my wrt54g and wrt 160n routers. The fans are rated at 12v .82a. The routers are 12v. Adding the fan will take the linksys power supply to the limit. I read that linksys can take up to 18v. I have a couple of laptop power supplies, one is 16v 4.5a the other is 15v 5a. Would these work and also would the fans be able to handle the extra voltage? Thanks for the help.
Sep 10, 2010. 7:08 AMatarthur says:
I'm surprised that none of the radio ham people haven't pointed out that BNC connectors are not the best for microwave frequencies which is why the WRT uses RP-TNC connectors. Also RG58 losses are considerably higher than other more suitable cables at these frequencies, you would be better off using LMR200 or similar.
Apr 3, 2011. 6:47 PMBradley102 says:
RG 6 coax works well at microwave freqs
Jul 10, 2010. 2:47 PMchamunks says:
Very much looking forward to the part TWO of this ible... If someone was looking to create a wireless mesh setup with a couple of these routers between myself and a few good friend/neighbors in my area how would one go about getting an amplifier for this sort of thing? I realize you can get pretty decent directional range but I figure this is a good place to ask this.
Nov 4, 2010. 3:40 PMchamunks says:
I am very much looking forward to the part three. I really like that you did the biquad dish I wanted to see someone post a better and more explained version of this concept for quite some time.

I dont really know anything about radio frequencies but I do know that I want a much stronger antenna than is purchase able. I think that this "ible might have just enough information to get me exactly where I want to be with my wifi setup...

If only I could install PF Sense into one of these routers.
Aug 22, 2010. 11:29 AMAkoi Meexx says:
Love the work done on this, and part two is just as awesome. But I'm a little confused here, what was the purpose of adding POE if you just made an adapter for it that plugs into a wallwart anyways?
Jul 10, 2010. 2:50 PMchamunks says:
Also would normal Arctic Silver Ceramic heat paste work to adhere the heatsink to the chipset? I have two wrt54g's (one is an GS and ones a GL) I always only thought that heat paste was just to improve heat conductivity between the chip and the sink and not to adhere. I've noticed my routers and two dsl modems tend to get pretty toasty and I would like to employ some of this hack for sure.
Jun 14, 2010. 12:08 PMAE6ZA says:
Incidentally, though the FCC is generally too busy to ordinarily bother with this sort of thing (barring a filed complaint), it is still a Federal Offense for a non-licensed person to repair or modify FCC Type Accepted equipment, which a router is. The magic number here is their average $10,000 fine. That being said, this is a pretty cool Instructable. Just keep the risks in mind.
Jun 21, 2010. 10:47 PMknowsnow says:
AE6ZA, KD6LYG...

I have been wondering if a licensed Ham radio operator could modify and use a router without fear of breaking any FCC rules. If so, what is the legal limit of wattage output for a router? I have been out of the loop for a while but this is the type of project I was looking for to just have fun with. I don't have any sending or receiving issues with my the routers in my home and can reach both from any room in my house and I had the whole house wire with cat 5 and jacks in each room when it was built, but I just want to see if I could Hit my FIOS router from the park down the street.
Jun 26, 2010. 7:46 PMsrainsdon says:
first off yes a ham can some of the wifi chanels are licenced ham freqs. legal limit is what ever the least you need up to 1500w. but if you dont have a mod router on both sides or a preamp you wont here one end.
Jun 14, 2010. 11:42 PMtbm13 says:
10k could be the issue if it were being redistributed. tho.. if for personal use there typically isnt much anyone can do about anything.
Jun 14, 2010. 3:41 PMkbeelitz says:
We usually don't think about Legal action when we're modifying components but hopefully the FCC is worried about more important things.
Jun 20, 2010. 12:57 PMNostalgicStone says:
I love it! Hey if you don't I would love to add a link in my instructable to yours, for people who are interested in taking this whole thing to the next level.
Jun 20, 2010. 11:09 AMUser1 says:
Great instructable! Very well put together. Being a noob at soldering, this tutorial gives me the confidence I can do this! Mighty nice wall of shame too! Look forward to more. Looks like you used a version 8 router? I'm wondering why that was chosen?
Jun 19, 2010. 11:14 AMbdlang says:
>>First finding a heat sink that fits the broadcom chip is impossible


Zalman and other manf. make small heatsinks for PC RAM use (available from NewEgg and similar) that will fit this purpose. I've used these with good success on the WRT56G series. Just be sure to purchase thermal adhesive compound to secure it to the chip.
Jun 14, 2010. 7:12 AMchrwei says:
does this model not have removable antenna? and if it does, does that tiny wire really make a difference vs the larger one you install for such a short distance?
Jun 13, 2010. 11:46 AMcheesphht says:
Okay, so it's a "beast" now. What does that mean? What are you doing here?
Jun 14, 2010. 7:35 AMbeatmeistah says:
Great job, This is a great tutorial. I'll give this a try. I have a wall of shame myself XD. I'll let you know if I have anything helpful to add, but this looks pretty great.
Jun 13, 2010. 11:03 AMgromit1943 says:
Is one a transmit and the other a receive antenna?
Jun 13, 2010. 3:26 PMNiceMan says:
You can choose how to use antennas one tx other rx, one of them tx+rx ... etc ... by software ... you might want to look for tomato firmware one of the best for this router just ggl "tomato firmware wrt54g"
Jun 13, 2010. 2:53 PMsturmey says:
nope, these routers run two antennas that both send and receive. that way you can orient them in a way that improves your signal. This is true for almost if not all routers that have more than one antenna. Very cool instructable. I like the idea, it gave me some good insight into PoE as well. Thanks
Jun 13, 2010. 7:47 PMmce128 says:
You can set one as Tx and one a Rx if you use custom firmware such as Sveasoft, or OpenWRT or similar
Jun 14, 2010. 5:11 AMsturmey says:
wow, I didn't know that. That could be very useful.
Jun 14, 2010. 7:19 AMmce128 says:
Indeed :) along with many other missing features depending on which custom firmware you pick... things like VPN endpoints, lots of low level control, etc...
Jun 13, 2010. 10:36 AMDasher says:
Awesome instructable. But i have a request. Do you think you might be able to put up a schematic of it?
Jun 13, 2010. 8:57 AMadamvan2000 says:
I love how this is several instructables in one, and all well described and photographed. Awesome job! ~adamvan2000
Jun 11, 2010. 8:50 AMDecepticon says:
Love your workshop. I am trying to build one in my garage like that. Nice work on the router. I have yet to mod it as much as you have but I use DDWRT religiously. Great write up!
Jun 11, 2010. 1:11 AMSinAmos says:
I really need a workshop. I have a few of these routers. I've upgraded their firmwares, but they never refresh IP addresses. I'm not sure what makes this a beast? Are you frankensteining it to something?
Jun 10, 2010. 10:07 PMkelseymh says:
This is a spectacular writeup! Have you been able to exercise your Beast yet? Does it function properly as both a router and a repeater?
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