LAN port?
This was brought up a while back and I forgot the answer.

Also, I have a rack mountable pc, I5 3240(i think) with16 gb ram and 4 ports. Would I be better leaving the router on its own machine or vm it on the pc chassis?

If you have a switch capable of using VLANs then you can run everything over a single port w/ pfsense though it's a nonstandard configuration
You'll have to set it up and configure only the LAN interface for the single port, then login to the webui and setup the VLANs and re-assign the LAN to the new LAN ... VLAN

For a basic WAN/LAN setup, it'll be easier to stick with using two physical ports

ETA: VM is doable too, but again it'll be easier with a dedicated physical machine

I will probably keep the mini for the router and make a backup copy I can spool up on the bigger machine, just in case the little one fails.
I have a TP-Link 24 port managed switch so vlans are covered. I am playing around with vlans for IOT, guest, office, and security. At least one of the ports is for WAN. I am thinking about a redundant WAN link over cell service. Our WISP gets knocked out every time the weather acts up.