So adding a SD Card to a Linksys WRT54GL is pretty simple.
Why would you do this you ask?
Because the WRT54GL Router runs linux natively and there is a shitload of homebrew firmwares available for this device!
Adding the SD Card adds the ability to install more packages than the onboard storage allows, Run a proxy like Squid with a half decent cache capability or even host your own website!
What do i need?
2. Some Wire
3. Soldering Iorn
4. Solder.. Duh!!
4. SD Card
5. SD Card Prototyping Board ( Optional) I used this to make life easier and picked it up on ebay great peice of kit. See Link BYVAC SD Prototyping Board Datasheet
Lets Get Started:
Removing the Cover of the unit is fairly straight forward. The Blue section of the router pulls forward from the black section. Just apply pressure top and bottom near the join and make sure you dont go crazy and snap the circuit board inside!!!
Once open identify the locations we will be soldering on to
We will be soldering 6 wires onto the routers circuit board.
Once you have soldered on your 6 wires solder them on to the SD Card in the following order.
Purple: SD Pin 1
Yellow: SD Pin 2
Orange: SD Pin 3 - If you are not using the BYVAC SD Prototype Board you must also jumper this to SD Pin 6
Grey: SD Pin 4
Red: SD Pin 5
Light Blue: SD Pin 7
Firmware Time:
Ok so Linksys never put this functionality in their software so we need to do something about this.
I used the DD-WRT v24 Std Generic Firmware.
Now you cant just install the Standard Generic Firmware off the bat. Well atleast i had problems doing this so.
Get the dd-wrt.v24_mini_generic.bin Firmware first. DD-WRT Download Site For WRT56GL v1.1
Now log into your router using the web.
Go to the administration menu then firmware upgrade.
Select your downloaded dd-wrt.v24_mini_generic.bin file.
Click upgrade.. cross fingers.
Seeing this message is good because you havent trashed your router!! :D
Now log into your router using the username root and password of admin
Now repeat these steps and upgrade to either the mega or standard firmware. Because the mini does not contain SD Card Support.
Once done log back into your router. Go to the services Menu and enable the SSH service. Save your changes.
Go to the administration page and enable SSH Management and enable SD/MMC Support using the default options.

Save and reboot your router.
SD Card Troubles.
I had a few issues with my router booting rather slowly after the SD Card mod.
I overcame this by formatting the SD Card in EXT2.
Done!
You now have a customisable linux operating system running on your router and some additional storage!!
There is a Overclocking option in the main dd-wrt menu i suggest you dont touch this at all!!
The broadcom cpu gets rather hot as it is so my next hack will be a heatsink/fan solution for it. And even after i have done that i wont be touching this function.. Honestly why bother!!
Now i really should go and do something productive like service my car!!
Source of Hack: http://www.hendlsofen.de/WRT54GL/eng/WRT54GL_SDMod.html
Peace out for now
Patrick