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Pentium D processors are pretty power hungry, so factor that into your thoughts. Also make sure you put a modern OS on it that is getting security updates. It probably has Win XP or Vista installed which isn’t safe to connect to any network.
It should work fine as a router as long as you don’t enable any of the packet inspection features. For basic routing and firewalling for a home network it should be plenty powerful. I would personally put a small SATA SSD in it as the main drive and ditch the 90GB HDD.
As an additional idea, if you put a larger SATA drive or two into it you could make it a NAS.
Code should absolutely speak for itself. But the occasional comment is still good to explain the ‘why’ of the code when the why isn’t very obvious, often due to a niche requirement. Also any time you have to break out a hack, that needs comments up the ass, what was the bug, what URL did you find the fix at, why does this hack work, etc etc. It’s very satisfying to go back and remove those hacks after they are no longer needed, often because the underlying technology fixed the bug that had to be hacked around.