Doing a few throughput tests on IPCop on the OB800 I noticed it was working very hard. A bit of poking around revealed that tweaking could the hard drive settings made a lot of difference. Switching on 32-bit access and unmasking interrupts during operation improved network throughput and dropped CPU load at the same time. I guess logging onto CF was taking long enough to affect the network.
Anyway, the net result is to add the following to /etc/rc.d/rc.local
/sbin/hdparm -u1 -c1 /dev/hda
This also works for DSL, though the file to modify is /opt/bootlocal.sh
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