Make one or more partitions on this 2nd drive.
Now, buy a copy of Norton Ghost and make a image of your "C" partition,
and save it on the 2nd HD. Ghost runs from a bootable floppy.
Make sure that you have FDISK and Format on your startup floppy then
boot windows from this startup floppy. You can now FDISK and Format the
first HD into smaller partitions. All the data is on the 2nd HD. Now
boot Ghost once more and restore the image from the 2nd HD back the
first partition of the 1st HD.
Another way to go: If you buy a non-OEM name-brand HD, chances are that
it'll come with a utility designed to copy windows files straight across
to the new drive and make it bootable. Every now and then just wipe it
and do the copy all over again. If your original HD craps out you can
reverse the drives or reverse the copy.
Even if you buy an OEM hard drive, you can sometimes download the images
to make your own HD installation floppy. Some of these utilities will
even work with other brands of HD.
I'm finding a fujifilm smartmedia reader that I got for Christmas
useful. This is a pcmcia card for a laptop so it slides right into the
machine, and has a slot you can slide smartmedia cards into. I have a
lot of 64-meg cards and a couple of 128 meg cards laying around that I
use for my digital camera. With this setup I can also use the cards for
temporary backup when I don't need them for photos. The only problem is
that the smartmedia cards are formatted for DOS 8.3 filenames, so to
get long filenames to work you have to either zip your backup to an 8.3
filename before copying it over, or reformat the flashcard. I'm using
FreeBSD and format my cards to UFS, but I assume you could format them
as Fat32 under Windows. (Yeah, I know this is a lot like those USB
flash drives. But USB flash drives don't fit in my wallet the way those
almost paper-thin smartmedia cards do)
I also vaguely remember someone a few years ago talking about putting a
scramdisk partition on a smartmedia card. The partition could be given
an 8.3 filename, but when you mount it a scramdisk partition acts like
a FAT32 filesystem and can store long filenames.