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OpenWrt
Using OpenWrt and off the shelf hardware, you can build a PirateBox for as little as US$30.
Hardware
PirateBox 1.0 can be installed on most wireless routers that support OpenWrt and USB 2.0 storage. Our target hardware is the TP-Link MR 3020 and TP-Link MR 3040. Check out the OpenWrt wiki for more info about the MR3020 and MR3040.
For a list of routers that support PirateBox, please check out the OpenWrt hardware table.