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I don't know whether I'm missing something obvious here, but when I download the TomatoUSB 2.6 VPN build (from here), and try and install the included .trx file in the default Linksys router "Firmware upgrade" screen, I get the error "incorrect image file!"

I think it wants a .bin file instead, and indeed the default Tomato firmware comes with a .trx file AND various .bin files, so why doesn't TomatoUSB? How should I install TomatoUSB onto this router? Is it safe to just rename the .trx file to .bin, or do I need to get some other file to install it?

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It sounds like the author didn't package the correct files. Contact him for support. Although I highly suspect that Linksys routers do not have Broadcom chips. Try a different version of the firmware see if the archive contents changes. A trx file IS NOT a bin file doing so WILL NOT work. –  Ramhound Mar 8 '12 at 17:54
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2 Answers

The answer was that the TomatoUSB image was too large (over 3MB) to be installed directly through the Linksys firmware. I first installed the regular Tomato firmware, then used its "Upgrade" screen to upgrade to TomatoUSB (you ARE allowed to upgrade to a .trx file from the regular Tomato firmware).

This guide actually tells you to install the "mini" version of DD-WRT first, for some reason, but it works equally well with normal Tomato as it does with that.

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Yes, you can change (rename) trx to bin. As far as I remember, trx is for ASUS routers. But you must check very carefully that you have the correct firmware for your router.

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Nope, that doesn't work. I suspect what I need to do is first install DD-WRT mini, because the default Linksys firmware can't flash images larger than 3MB (which TomatoUSB is). –  Jez Mar 8 '12 at 22:13
You should go to tomatousb.org or linksysinfo.org/index.php and study. And you are probably right in installing DD-WRT mini first. –  troels Mar 9 '12 at 0:25
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