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Have you tried a different mirror?

Great tips, thanks! Yes, I am hoping to get at least 4 ports, or a mini PC with a full PCIe slot that would let me add a 4+ port Intel NIC. I'm leaning towards the latter currently, as it offers me some ability to update components as time goes on.

I would refrain from a modular PC unless it is really great with power efficiency (most are not). The dedicated firewall boxes have less unneeded components, like audio chips and stuff. Your firewall is a 24/7 device where it makes a difference if it draws 10 Watts more or less. Also, AFAIK, 4-port Intel PCIe cards have 1 Gbps only, whereas most china firewall boxes have 4x I226V with 2.5 Gbps build in.

You can get 4 port i226 cards.  They are all over AliExpress.  I was looking at them and just ended up ordering a Fenvi i226 2 port. 

I have a Dell 7020 SFF i5-4590 8GB RAM that draws about 25 watts average. It's a little more electricity but it would take many many years to make up the difference in electricity cost. 

 

You could switch to the community release and donate some money every year. 

https://opnsense.org/donate/

Successful upgrade from an Intel i350 two port to a i226 two port. This is a Fenvi i226 two port card that I ordered from Aliexpress.   

Card was on a etrackid that didn't correspond to any of the firmware. It was on v2.23 but the etrackid showed 8000397.   

Tried flashing 80000425 from the 1MB.  No go.  Tried in Arch linux, then booted into windows.  Would not flash and kept giving a security error in the log file.

Finally tried the 2MB version and that worked. 

Renamed the igb0/igb1 to igc0/igc1 in the config.xml file and installed the card.  At first, was able to get into Opnsense via web, but gateway was not showing.

Rebooted modem and everything seems to be working as it should be.

Thank you!!!!!