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Thanks !! Finally had a few minutes to try this out, and it worked perfectly!! All is well in the world.

The OPNSense web site might be stronger in their emphasis of the alternative path to install if you have problems like these. A sentence in the middle of a long page, does not stand out.....

I'd still like to know why pfSense would boot from USB, but OPNSense (except NANO) would NOT boot.  ????

Except for the NANO version, I cannot get the current release download to boot on any computer. I have 3 test machines, all different brands. The checksum validates, and I have also downloaded from a couple different mirrors just in case. (not that I don't trust checksums, but drawing at straws here.)

The same 4gb USB stick will boots in the same ports on all 3 of these computers, with pfSense.

But OPNSense will no boot.... except for the NANO image, which boots fine.

I have legacy boot turned on, and the USB stick as #1 in the boot priority. I've installed Ubuntu and pfSense on these machines, as a test case to see that everything is working. OPNSense seems to be the only exception.

Neither the HP T620+ or the Sager laptop recognizes the USB as a bootable device. The Lenovo T73 goes gibberish batsh_t on the screen when attempting to boot and hangs (and this box has an earlier OPNSense installed!)

Note that I burned the USB stick with BalenaEtcher on MacOS - the same way I burned an earlier OPNSense USB stick and installed on the Lenovo. I have not tried RUFUS on Windows, as a path, or even a dd at the command prompt; as Etcher has been flawless on everything else.

What am I missing in this process? The T620 is the end game target for the OPNSense machine, replacing the Lenovo T63 primarily due to USB2 based ethernet as the dual nic option (no PCIe slot, except for a mini-PCIe, but then no place to pull the RJ45 and cable to the outside of the box. - and idk if this option is even supported)

So picked up a t620+ and installed a Intel i350 quad port ethernet.

OPNSense would only boot, IF I used the nano version
The booted copy allows me to select detected ethernet ports and assign IP address (or allow DHCP, which, if connected to the LAN, gets a valid address).
However, I cannot connect to the assigned ports.
I moved the T620 and a Win Laptop onto an isolated network, with only these 2 devices and a ethernet switch, manually set IP addresses but ...........

When I attempt to PING the T620/OPNSense machine, I get a "destination unreachable" BUT with all packets sent, received and zero packet loss.

As I can't attach to this OPNSense box, I am limited as to what I can perform at the console.

Suggestions??

It does, but there is no place to put the external ethernet connector. :-(

I have a couple Lenovo M73 thin clients, all with 6 USB ports, displayPort, 1 gigE port, VGA, 4th gen i5, 8gb ram, 128gb SSD boxes, and have one set up right now as OPNSense. However, the 2nd USB port is currently the Apple device, which works great, but is bandwidth constrained by USB2.

I'd like to find one with USB 3 that would support the gigE connection.

The Plugable USB3-E1000 is NOT OPNSense/pfSense/FreeBSD/HardenedBSD 11.2 compatible, so that's going back.