Using this a great big thanks to these guys.

Have edited with *******

10.5: Create a three-partition Boot Camp setup
Authored by: pbw on Sat, May 10 2008 at 7:55PM PDT
I'd like to thank the contributors to this hint. I had Leopard and Boot Camp installed on a single drive in my MacBook. I replaced the drive with a 250GB HD and wanted to create 2 bootable OSX partitions and keep my Boot Camp partition. I did the following (using a combination of comments here):
1) Cloned my original OSX partition with SuperDuper.
2) Clone the Boot Camp partition with WinClone.
3) Formatted the new drive with Disk Utility (1 partition).
4) Restored OSX with SuperDuper.
5) Used the Boot Camp Assistant to only create the Windows partition then quit.

***Didnt do this as i was starting from fresh***

6) Restored my old Boot Camp partition with WinClone.

*** Ignored 6***

7) Used Disk Utility ***from cd*** to resize the Leopard partition. Then created a new MacOS Extended (Journaled) partition with the new free space.
8) My Boot Camp partition failed to load with a blue screen and "UNMOUNTABLE_BOOT_VOLUME".

***(mine actually went into a constant restart loop)***

9) Installed MacFuse and NTFS_3G.

***(I didnt do this as i was happy for my 3rd partition to be fat32***

10) Opened the boot.ini file on the Boot Camp partition within OSX using TextWrangler. Changed the 3's to 4's. (Used Disk Utility to find out the new partition # assigned to Boot Camp after I created the new OSX partition).
11) Rebooted into Boot Camp and it worked!


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10.5: Create a third NTFS partition with Boot Camp
Authored by: chazsconi on Fri, Jun 13 2008 at 11:06AM PDT
Thankyou PWB for these simplified instructions. However I wanted my extra partition to be NTFS, which with MacFuse and NTFS_3G will be accessible from Leopard and XP. To do this I did the following:

1. Followed all of PWB's instructions to step 11.
2. Checked XP still booted.
3. Went back into OSX and used Disk Utility to format the new partition with NTFS instead of MacOS extended. (This option is available if you have got MacFuse/NTFS_3G installed)
4. Step 3 will report an error due to a permissions problem
5. Go to the terminal
6. Change the ownership of the disk: sudo chown user_id:operator /dev/disk0s3 Replace user_id with your logged on user id.
7. Re-do step 3 in Disk Utility which should now succeed. Change the ownership back to root: sudo chown user_id:operator /dev/disk0s3
8. Done. You should now have 3 partitions: MacOS with Leopard; NTFS with XP installed and between the two an new empty NTFS partition

The only minor problem I have found with this is that within Leopard if I go to start-up disk within settings it cannot see the XP partition, so I can not reboot to XP from within Leopard. I have to reboot, hold down the Option key at startup and then select Windows from the menu manually.

Something else I have learnt from this exercise, which involved an lot of trial-and-error and rebooting, is that it's not a good idea to create or change any partitions from within Windows using the Disk Management snap-in in Computer Management. This either fails, results in partitions that OSX cannot see, or causes Windows to fail to boot once the partitions are created. It may be possible to do this successfully using the extended options available from the command line in Windows, but I didn't try this. In summary only use OSX to mess around with the partitions.

*******************************************************
FOR 10.4 i found that the same procedure didnt work. I had to change the system clock to allow bootcamp to work as it was a beta (try 07.06.07)
Then used bootcamp as normal and setup windows (i had done this back in 2007 but used NTFS as windows and wanted to reduce the size)

Once windows was installed I used a 10.5 install disc 1 to access the disc utility. i was then able to do the same steps as before from steps 7 of PWB's post

I now have an XP (Fat 32) SERVICE (FAT 32) and Macintosh HD (Macintosh Journaled) Partitions on 10.4 and 10.5 OSX

This means i can now save a norton ghost image of windows to the service drive, when i want to reinstall windows i can boot from the ghost boot CD and recover the XP image from the service drive.