I'm just curious what a custom built setup like one with the Intel Atom processor costs...for everything...more than $200 USD? The Asus routers are high end consumer grade and a great value for the price (currently around $150 USD for the RT-N66U). They feature more bells, whistles and customization capabilities than most people need for home or small business applications. Many users feel the performance of it as a dedicated wireless AP alone is worth the reasonable cost of these routers. However as you have shown there are some home and small business users who might benefit from higher performance wireless routers.
There are many other higher end solutions available if you are willing to pay for them but there are always the cost prohibitive factors that determine purchasing decisions. It would be interesting to know what the total final cost would be with your custom router and wireless setup...up to $500 USD? If you wanted good wireless performance then the RT-N66U and the RT-AC66U routers are great even when used as inexpensive dedicated APs. I am wondering wouldn't you want to keep the Asus in your custom setup for its wireless performance alone. Also, since the wireless performance setup is critical for many home and business users how much would be the entire custom router and wireless access point setup like the one you put together would be compared to simply purchasing a business professional grade wireless router from a company like Cisco, etc..
From a quick visit to Newegg, LogicSupply and Crucial:
DN2800MT Motherboard $110
1 GB RAM $10
Case (M350) $40
AC Power Adapter $25
Riser card + IO shield (to allow the 2nd NIC) $17
Additional Intel Gigabit NIC $35
Intel 6300 Ultimate N 450 Mbps $35
mSATA 32GB $51 (this is a luxury, I would say just boot from a USB stick)
Total (excluding the mSATA) is $272 for a single Wireless N card, or $307 for dual Wireless N cards (for simultaneous 2.4 and 5.0 GHz support -- another luxury, there are relatively few 5.0 GHz devices out there yet).
This is a completely fanless solution that idles at around 10 W (maybe a bit more with the Wifi cards). The Asus idles at 21 W, and I calculate that the Atom is 5x - 7x more powerful than the Asus.
Note that I didn't spend any time finding the lowest price, I just knew which bits I needed, and quickly searched for them to have a rough idea. I'm in the UK but these prices are in USD and for the benefit of what I assume is the majority demographic of this forum. Of course, if you have any parts already (like a case, power supply or NIC floating around), then cost drops accordingly.
Versus the RT-N66U, at $170, which as you said, offers plenty of bells and whistles for a pretty good price, and covers the majority of needs for the majority of users, in a pretty luxurious way. It's a GREAT little router!
Commercial routers are almost an order of magnitude more expensive, and with no guarantee of performance (in a lot of cases they are a huge rip-off). You would also struggle to find one with e.g. dual-band 3x3 MIMO Wifi + gigabit + all the other features that retail routers provide. Then there's form-factor (usually they're not small), noise + heat + power-consumption, etc.
So of course I'm not advocating that the home build is for everyone; in fact, far from it. I could very well choose to live with the RT-N66U and be limited to "just" 200 Mbps. However, as a geek, I rise to the challenge of eking out every last drop of performance from my broadband, and if that requires me to come up with a kickass home-build, then that makes me happy because I have an excuse!
Note that I haven't made up my mind. It's still a lot of money for what should be a commodity device; but I do realise I am in the minority with my fast broadband.
Regarding wireless performance: I had the RT-N66U for three weeks, and to be honest, I didn't notice the difference. My iPhone 5 supports 5GHz, and my laptop has an Intel 5300 which is a pretty great little card that supports 3 streams on both bands (I benchmarked well over 200 Mbps to my Gigabit server on the 5 GHz band), and yet, in normal day to day use, there is absolutely no perceptual difference when compared to my current 2.4 GHz 4+ year-old Draytek router that is now serving as an AP. It's not like I'm using my wireless devices to copy multi-gigabyte files; so at this stage, for me 5 GHz wireless is cool, but nowhere near the top of the list of my requirements. I should point out that most of my home computing is done on a Core i7 PC on Gigabit Ethernet.
Thanks for your feedback, and I'd be interested to know how you feel re. homebuilt vs. RT-N66U now that you know it can be done for under $300.