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I would recommend an Asus router of some sort. I have 4 of them and they all seem good. I wouldn't recommend a D-link, since I find they are not as "smart" as an Asus, and they are likely to have more bugs. I feel the D-Links hasn't kept up with the advances that Asus has brought to the market.
From the replies on this thread it seems that most people would never build a router out of an old computer. The "built" router will take up a lot more space, use more electricity and make noise. I think this is project is something for a true "geek" and not for a normal user.
I would personally never flash an Asus router with aftermarket firmware unless it had a feature that I needed. Asus does a fine job, and they will have better QC than some guy at home. The Asus routers are already designed for enthusiasts, and has pretty well every setting an enthusiast would need. I have flashed several aftermarket firmware that were worse than OEM.
I think the router market has become "fashion" lately, with new high end router with more and more antennas, and higher prices popping up every day. Like all high end products, there is rapidly diminishing returns. The sweet spot is probably at under $100.
I would personally recommend an Asus RT-N56U.
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