Community ISP Project Using OpenWRT, ZeroTier, and Salvaged Hardware – Advice Welcome

Installing and Using OpenWrt
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Hi everyone,

I'm working on a nonprofit-cooperative ISP project in Northern California called PonyXPS_ISP, using OpenWRT and other open-source tools to deliver low-cost, privacy-respecting internet to local nonprofits and underserved communities.

We’re combining:

  • :brain: OpenWRT routers (repurposed hardware + mesh potential)
  • :globe_with_meridians: ZeroTier for secure private network bridges between nodes
  • :brick: Grav CMS for administrative dashboards (local-only or remote)
  • :high_voltage: Solar, battery backup, and fallback networking in the design
  • :floppy_disk: Older PCs as edge routers, caching servers, and data sync nodes

I’m still a novice with OpenWRT but eager to learn from others who’ve:

  • Built community or cooperative networks
  • Run mesh or multi-WAN systems on OpenWRT
  • Combined VPN-like solutions like ZeroTier with OpenWRT
  • Used older routers or hardware in creative ways

The goal is to create a replicable local ISP model other nonprofits can adopt. We’re already testing things like captive portals, form-based dashboards, and remote node access.

Would really appreciate suggestions or examples, especially for:

  • Load balancing or failover WAN setups
  • Using OpenWRT in low-bandwidth or solar-powered sites
  • Anything to make node management simpler and resilient

Thanks!
— PonyXPS@proton.me
https://PonyXPS.com (still evolving)

1 Like
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I have not much to add, as I lack first hand experience, but I would ask you to look at Tailscale as a potential contender for zerotier. (The company even supports the fully free Headscale replacement for their commercial tailscale coordination server).

Ah, regarding older routers, I am all for keeping these operational as long as reasonable, but consider putting in a reasonable lower limit so you will be able to follow upstream OpenWrt for some more time, so likely more than 8 MiB Flash and more than 64 MiB RAM, see here flor more details:

3

Keep in mind that some older PCs are pretty inefficient, power wise, so measure power consumption first before deciding to have a PC run 24/7. Also these can get flaky (just think of the electrolytic capacitor quality issues) so make sure this system does sufficiently smooth fail-over.

4

Probably ask here:

Refurbished routers can not usually do crypto at the speed you call "internet".
You will need a real server users can VPN to from public canteens