Moving settings to JFFS always carries a downside: its content doesn't get backed up along side settings. When Asus moves a setting to nvram like they did on the HND platform, they can integrate it within libnvram so the settings is transparently handled by saving/restoring settings. I do not have that option, I cannot modify the "large_nvram" table that they implemented with HND models. Moving OpenVPN-specific settings to JFFS might be an option since the certificates already reside there, but it would require major code changes throughout the entire firmware to handle that change. Not the level of development I am willing to invest specifically just for a 10 years old model that's probably on its way of being phased out. The amount of work + testing + debugging would require multiple weeks of work just for that.
The RT-AC68U is the only supported model that still has 64 KB of nvram.
Before nvram is committed
nvram commit there allow almost infinite number of nvram values, because those nvram variables are only in RAM before committing, but can still be used by the system, so maybe allow all openvpn variables to just exist in RAM, load from jffs into RAM after each boot?
It sounds like moving to jffs, but not exactly, it might be a shortcut.
But the premise is to remove the nvram variables of openvpn, and once they are set, they will be ready at any time.
I mean, maybe you can remove the variable about openvpn.
But allow to configure them when needed, this will restore the functionality of 5 clients.
then someone who needs 5 clients can do a custom script to feed the needed variables into the RAM (uncommitted) nvram.
I've never thought doing subtraction was a good option for existing functionality. unless it's replaced with something better.