Ok I've just read over my assignment brief again, it's a little simpler than I thought which is good

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@taustin, cost is an issue of sorts I have to look at it from the college's point of view they only get so much funding from the government etc. There is a medium budget, it's a case of if you really need it you'll probably get it unless it's a stupid request.
Getting an SSD hard drive would boost the IPCop's performance I'm guessing by quite a bit, it will boot into windows 7 twice as fast as normal drive from what I've read. There not all that expensive, it would probably be worth it for the performance increase in my opinion.
@up4fun, basically I have to re-design the network in terms of security, here's the general layout:
------//Clients//------------------//DC, DNS, DHCP//---------//Security//----//Internet + VPN//
------------------------------------|Web Server|
-----------------------------------|Print Server|
----------------------------------|Exchange Server|
| 20 Network Printers|--------|Windows File Server|
|350 computers (roughly)| -> |Windows Domain Controller| -> Firewall -> ISP Router -> VPN
//Networks//
Green: Around 350 PC's plus 20 printers, couple of switches etc... All connected via ethernet. To my best knowledge the printers and PC's are on different subnet's (handled by the Win server)
Blue X2: There are two wi-fi networks, the unsecure one for students and the staff one. The student one is on a completely seperate network I think

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Orange: The Web server has a windows sharepoint that can be accessed via the web with a user name and password checked against the windows DC, it runs on https only. The exchange server which deals with all the emails most also be accessed from the outside.
If I put in an IPCop firewall I'm guessing it would look something like this:
------------------------------------------------VPN (Net to Net and Roadwarriors needed)
--------------------------------------------------^
--------------------------------------------------|
---------------------------------------------- ______
-------------------Student Blue************| IPCop |
-------------------------------------------- / -----------\
-------------------------------------------/ ------|-------\
------------------------------------------/--------|------- \
-----------------------------------------/---------|---------\
--------------------------------------Staff Blue__Orange Net__Green Net
-----------------------------------------^-----------^--------Win DC
-----------------------------------------| -----------|------------|
-----------------------------------------***************************
-------------------------------------------------Pin Holes
Excuse the poor graphics, I'll see if I can make a better one tomorrow! There shouldn't be any DHCP running on the firewall really maybe for the wifi networks, other than that they will either be assigned statics or handled by the Windows DC. I guess I'll have consider port forwarding for the orange network as well.
I doubt there are any VLAN's being used in the college, network ain't all that great to little staff at the moment. There needs to be a VPN, I'm not sure if that's being handled by the Win DC... I'll ask tomorrow.
Content filtering is currently done down the line, it's ok. But they have choosen to block any uncatergorised sites on the firewall at college as well, which is kinda stupid when your trying to research, they have to manually add exceptions. Throwing Dansguardian in instead wouldn't hurt I don't think, they aren't even filtering google search or blocking direct https traffic it's all transparent. Using Copfilter might be a good idea, but I'm guessing that would put alot of strain on the IPCop with all those requests...
Thanks for the help!