With common mode choke coil should be better, "CMCCs help improve skews and reduce electromagnetic noise", see http://www.epsondevice.com/webapp/docs_ … d=ID001683, page 8, and here http://www.murata.com/products/article/pdf/ta09b1.pdf.
About the overcurrent protection, for the 5V USB power supply I've used a dc-dc converter from a Car Cigarette Powered 1000mA USB Adapter Charger similar to http://www.dealextreme.com/p/mini-car-c … -12v-48925. These have integrated overcurrent protection (at 1000 mA indeed, but I like it)
About the 8M flash, I think it would be easier to use one 8M or 16M flash chip just because it has already been done and is well documented, see here https://forum.openwrt.org/viewtopic.php?pid=156473. Your idea is good, in essence it is adding an additional logical SPI interface, the drawback is I think it will require a kernel hack, and it takes a lot of time. I've thought also for adding an SD flash card (4GB, 8GB, 16GB...) on such additional fast SPI interface, or better - in place of the original 4MB flash chip, but I had no time for implementing this idea. Who would need and USB interface then? Just joking, USB's good, you could always plug an USB fan or USB coffee warmer if you have'em
A dir615 cluster? MEGAZORD!!!