Aye it's totally possible. I built a router a bunch of years ago using Freesco running from a floppy. It was kinda slow. :P
I can't be of much help though as many moons has passed since then.. So I'm interested too. My biggest worry (if it is a worry) is that a router is often your first connection at home, so I imagine you would have to think about security, especially if you have it as a media server as well. But again this is only what I imagine, I don't actually know. Will follow thread.