I dont think that its possible cause traffic is coming to the computer

Put a gateway address on NIC 2 and use the 'route' command to define a static route on NIC 1 for 192.168.0.0/24

NIC2 have the ISP gateway via DHCP. But the VPN tunnle - what NIC does that run on ? Lets say i connect to an outside PC via VPN, can that outside PC reach NIC1 aka my LAN trough NIC2? That i dont want

I think your limited with your options in XP however  you can enable routing in XP by changing the following registry key (start run regedit to open registry for modification)

Locate HKEY_LOCAL_MACHINE\System\CurrentControlSet\Services\Tcpip\Parameters, find a value called IPEnableRouter. double click it and set the value to 1.

You can then play around with routing in the firewall

Me again :)

as a after thought? does your router allow for additional VLANs? you could just add one and give the other card the relevant IP and your away.

Also have you looked into hamachi as a VPN solution - it works very well for some of my clients and is stable and not to mention FREE!  

Cheers

Tony

I have a dir-655 and i cant find anything about vlan.

Just to clearify myself abit (my english sucks sorry): The VPN tunnle i use is for cryptation, nothing else :) and i want to separate the LAN from the WAN.

I gonna try play around abit with above suggestions and see, thanks!

And yeah, hamachi is a great tool :)

If this sollution is impossible i can consider another idea that i have: Using only NIC1 and VPN on top of that, but how do i make sure that my local shares is NOT availible on the VPN network? (sharing video/music etc to my popcorn hour) - or is that possible even? Im lost :S

As far as the network shares, on properties of NIC2 in Network Connections turn off File and Printer Sharing.

Thanks for the help, will try these tips and see how it goes!

Just add static routes from the command prompt. e.g.:
route -p add 192.168.0.0 mask 255.255.255.0 192.168.x.x metric Y 192.168.x.x
where 192.168.x.x is the IP address of your NIC 1 and the metric is a value that is higher than the metric for internet traffic on the other NIC
Do a "route print" first to see the current system routes...

There is no need for static routes in this situation.

"Just don't have a default gateway on NIC1 and have one on NIC2."

Shall i still use the DNS on NIC 1? (192.168.0.1)

Sure any DNS that works is fine...actually, here's what I'd do.  Because you  have other machines in your (home? if it's a domain then this is more important) network that may use DNS to locate each other, you don't want to register NIC2 in DNS in case other machines then start going through the ADSL router (slower most likely) to get to this machine.  So, on the off chance that the your internal router does take dynamic DNS registrations, I'd just use the ADSL router, or it's own IP, as the DNS on NIC2.  It won't *work*  but since it's almost impossible to really turn off dynamic DNS registration in Windows, you just want something that fails really fast so that it rolls over to the DNS on the other card when looking for resolution.
I probably didn't say that right. :)  But try just using the ADSL router for DNS on NIC2 and the other router for NIC1, should work fine.

Good idea, i'll try that too! thanks :D