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3 partitions - NTFS, FAT32 and HFS+ without reformatting! Possibly more...
Authored by: gabester on May 08, '08 08:46:44AM
I just accomplished this in a slightly similar way, but you won't need to reformat and reinstall OS X - although you will need to access the HD either via the Leopard Install DVD or another Mac in target disk mode:

1. Use boot camp to partition your drive. Set the size of this partition to equal the combined size of the partitions you want for Windows and your other partition.
2. In Disk Utility, select your BOOTCAMP partition, go to the erase tab, and reformat it as HFS+ (journaled) - as Disk Utility can only resize or split journaled HFS+ partitions.
3. In Disk Utility, select your drive, go to the partition tab, then select the partition you just erased and split it with the plus button. Be sure to size the last (lowest) partition to equal what you want for Windows.
4. Still on the partition drive tab, delete the "middle" partition (the partition that is not your intended OS X startup volume and not your intended Windows volume.)
5. In Disk Utility, select your intended Windows volume and erase it with a MS-DOS (FAT) volume format.
6. In Boot Camp you should now be able to continue installing Windows (i.e. it should think you again have a "normal" boot camp disk.)
7. When the Windows installer starts up it should only see the drive you intend to install Windows on. (I installed Windows XP but this should work for Vista as well.) Reformat this partition to NTFS if you desire, and install Windows.
8. Once your Windows install is complete, access your drive without booting an OS on it (i.e. boot from your OS X 10.5 Install DVD and/or use target disk mode with another Mac).
9. This is the tricky step - open Disk Utility and UNMOUNT (do not eject!) all the volumes on your intended disk. While Disk Utility seems willing to let you modify your free space partition, it was displayed out of order on top of the Mac OS X and Windows partitions which made me nervous - as did the warning "This disk appears to be partitioned for Boot Camp. Changing the partition map may make this disk unbootable using Windows." (Do keep Disk Utility open to unmount your hard disk after each of the next two steps.)
10. In terminal, use the command "gpt list disk{x}" where {x} should just be the disk number for the drive you want to view the partition table of - you can get this information out of Disk Utility. This command should list 3 active partitions; #1 is your 200MB EFI partition, #2 is your Mac OS X partition, and #3 is your Windows partition. There should be free space in 512 byte blocks between your Mac OS X and Windows partition equal to the size of your other intended partition deleted in step 4 above.
11. (Remember to unmount all the volumes of your intended disk again in Disk Utility before this step) In terminal, use the command "gpt add -b PARTITIONSTART -s SIZE -t hfs disk{x}" where PARTITIONSTART is the block address where your free space starts and SIZE is the block size of the free space as determined in step 10 - the free space starting after your Mac OS X partition and extending to your Windows partition. (NOTE: I added in Apple's preferred 128MB buffer on each size of this partition by adding that amount to PARTITIONSTART and subtracting 2*128MB in blocks from SIZE. (This buffer size number can be determined from the space between your EFI and Mac OS X partition.)
12. Use Disk Utility to reformat this new partition as desired - I made mine FAT32 to share files between OS X and Windows. It may appear "out of order" above your Mac OS X and Windows partitions in the partition tab until you reboot.

At this point I found that my Windows XP install would no longer boot continuously blue-screening - I took the lucky guess of figuring that the boot.ini file needed to be edited to reflect that the Windows boot partition was not now number 3 but number 4 in the partition table order. Counterintuitively, after step 11, the gpt index of the partition is still number 3 (your middle partition between OS X and Windows will actually have index id#4) but, apparently, XP just looks at the partitions in order in the MBR wrapper inside your GPT on your drive. To edit the boot.ini file on the Windows volume from OS X, I installed MacFuse and NTFS-3G and pico. I simply changed the 3's to 4's and saved the file. When I rebooted into windows this time it came up successfully, as did the FAT32 volume; since I'd updated my Boot Camp Drivers to 2.1 already it even sees the GPT partitioning of the drive correctly from Disk Management.

After testing this a bit (verifying these steps, seeing how many partitions I can create in what order and whether they can be bootable) I will write this up as a full hint. My goal is to be able to have at least 4 bootable partitions - preferably with 2 available for XP/Vista - which I think will work on this hint right now. Previously, I had luck with attaining this configuration by formatting my drive as MBR but the limitation there was that OS X will not install onto an MBR disk - I had to image clean installs onto their partitions from another (GPT-formatted) disk.

I would guess that the method outlined above could be used to make many more partitions, and as long as the partitions that you need to be able to boot windows are among the first 4 on the drive (you go crazy and delete the EFI partition at your own risk - when I had my drive MBR formatted I had deleted the EFI partition without apparent consequence to OS X updates from 10.4.6 to 10.4.11 and 10.5 to 10.5.2.)

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