Alternatively, repeat above steps in reverse order. ie. hard wire secondary router to your primary router. Install and configure openvpn and ensure it is working with ExpressVPN. Then modify the configuration to use wifi to connect to primary router.
Openvpn is more demanding and you may have to spend US$150 if you want anything faster than 30 mbps.
Asus sell some routers with openvpn client - RT-AC86u with RMerlin modified AsusWrt software can do 170 mbps according to PIA, or 75 mbps with OEM firmware.
Also, not many devices/operating systems can do both wireless client mode AND vpn simultaneously at very HIGH vpn speeds. Someone may be able to offer some suggestions. (An Archer C7 with openwrt may be able to offer speeds 10-18 mbps when configured as a wireless client and openvpn client, but don't quote me as I do not own one. I would search this forum for C7 issues before buying one for Openwrt)
Otherwise, you may end up requiring two separate devices. eg. TPlink TL-WA801nd v5 can offer 2.4 GHz wireless client using original TPlink firmware. Use another router for vpn depending on what speed you require etc.
I am fine with any protocol and speed around 30+ MBps,
Regarding connecting second router and have VPN on it, can't i use bridge instead of wireless client mode?
Can i use wired client mode instead of wirless client?
What will be pros and cons of the above two
Yes, you can wire WAN port from openwrt (vpn) router direct to spare LAN port of your primary ISP facing router. It is simplest solution. You originally specified wireless (bridge) connection in your original post.
For 30+ mbps openvpn speeds on OpenWrt, perhaps I can suggest you research Netgear R7800, Linksys WRT3200 (1200 & 1900). All of them have 'issues'. I don't own any of them but there are plenty of owners on this forum who use OpenWrt on them.
There is little or no open source support for any modem-routers. Only exception is for old Lantiq based modem-routers on OpenWrt.
I suggest you check the manufacturer's websites. As stated earlier, you can buy routers running OEM firmware which do one or other function, but not both functions simultaneously, but I could be wrong (Asus RT-AC86u comes to mind but I'm not hopeful - Asus call them 'Media Bridge' and 'VPN client')
I suggest you review my earlier post if you want to use OpenWrt for fast openvpn, and possibly wireless client/bridging in one router, quoted below:
If you want advice on other routers which can run DDwrt or Tomato, you will need to visit the corresponding forums. (I know from experience OpenVPN client on Tomato is not as 'robust' as OpenVPN client on OpenWrt.) DDwrt favour Broadcom based routers. Tomato development has stalled imho and favours old Broadcom hardware.
The setup i need to archive is wireless client mode / wireless bridge between primary and secondary router plus VPN protected wifi network on secondary router.
Is it achievable ? As I just read somewhere that it sexodnary router is on wireless bridge / client then devices connecting to it should be through wired / Ethernet
Please shed some light on this
It is possible with OpenWrt. For example, a single device could connect to main router in 'wireless client' mode using '5 ghz wifi'. Same device can also run 'openvpn client' and serve VPN service over '2.4 GHz wifi' and ethernet.
Otherwise, you will need to use two separate routers for wireless bridge and VPN wifi router. eg. a pair of suitable Asus routers using AsusWrt OEM firmware would work out of their boxes (eg. RT-AC57U v2/v3 with a RT-AC86U)
In your very first reply, the link you sent to setup wireless client as below, is also doing both tasks? I.e. connecting / setup wireless bridge and also broadcasting the wifi as new network.
“Set up secondary router as a wireless clientconnecting to your primary router. Ensure the secondary router's LAN subnet is DIFFERENT to the primary router's LAN subnet). https://openwrt.org/docs/guide-user/network/wifi/connect_client_wifi
eg. use 192.168.111.1 on secondary router.”
If not, please send me the complete guide to setup wireless bridge at 2.4 GHZ and broadcasting at 5 GHz using open VPN.
Also please name the best suitable router / hardware to achieve that.
2. Netgear orbi ac3000 series. Can it be used for
Wireless bridge and broadcast VPN secured wifi using openVPN protocol ExpressVPN?
IF NOT, then can it be used wired bridge (LAN TO WAN) plus broadcast open VPN secured wifi do it need openWRT?
3. Netgear R7000 can it be used with wired bridge(LAN to WAN) and openVPN secured wifi
If yes, do it needed openWRT to achieve that?
Sorry, I cannot advise which is best router. I already listed some popular examples for you to research which should be able to handle 30+ mbps openvpn speeds. ie. R7800, WRT3200/1200/1900. I do not own any of these devices so I do not know whether wireless client function work properly on these devices. You will have to search the forum if no other forum member is able to comment.
Unlikely any Orbi model can do what you want. It is sold as a mesh wifi product by Netgear. I'm not aware of any Dlink, Netgear or Linksys router offering openvpn client in OEM firmwares. Only Asus offers openvpn client in some of their routers. No Orbi model appears in openwrt hardware compatibility list.