>Has anyone tried this setup before?
Yes, sort of. Preferably, what you need to expand a router is a switch (http://duxcw.com/faq/ics/diffrout.htm). I made it work with both DHCP servers working. However it was a temporary thing just to test a router and PC for a customer. If you must have two routers, I would attempt to turn-off the DHCP server on one of them (probably the one without the wireless capability, which I guess is the reason you bought a second router) and also make it act as much like a switch as possibleóbypass the NAT. Finally, I use wire wherever possible, which to date has been everywhere. Larry