Sounds interesting. I always wanted to use a Raspberry PI as router (to have one as backup in case the OpenWRT Linksys goes down), but couldn't wrap my head around properly how to overcome the single network port (I think the usual recommendation is to use an extra USB network card/adapter). Can you elaborate more about this VLAN stuff (you would put your modem, your router, and all your machines on the switch... and in the switch you tell the router connection to double use the connection for WAN and LAN separated via VLANs? And put the modem into the "WAN VLAN" too?)
Ideally the PI also should to what the extra DSL Modem does… but I guess that's where the dram must stop. :D