Installing New Boot Drive ?

Sorry to double post but, had this in the wrong section.
Hello, fellow G4'ers.
Mine is G4 MDD 867 Dual CPU and has a giga 1.4 CPU upgrade, 1.75 GB RAM.
ATI 9600 Mac OS X (10.4.11). 400W PS
Still runs well enough for my purposes.. besides drives are pretty cheap these days, so why not.
I Have 3 drives total now. 2 are Internal, 1 is External (FW400).
1 - (original) Boot drive 60 gig (20 GB avail.)
2 - Maxtor 200 gig with 2 partitions,
a) 40 GB partition w/ 40 GB avail. and
b) 160 GB partition w/ 90 GB avail.
I also have a 250 gig FireWire External (bootable) drive that has a cloned, used CarbonCopyCloner,
backup of the main boot drive and still has ~ 180 GB avail.
I only want to replace the original (aging) boot drive BEFORE it goes bad.
I read somewhere here that a separate partition for the system alone, could b a good idea. can anyone confirm this for me ?
I got and installed the 2nd drive myself (Maxtor 200 GB), so I think I can do this.
I need to be sure, as to a plan of attack here (software-wise), and appreciate any input as to a good way to do this.
I'm sure there are a few ways it can be done.
My best guess's are;
1-get the new ATA drive (500 gig drives can be had for under $100) Any hot tips here ???.
(How's this sound "500GB Western Digital Caviar SE16 7200rpm 8.9ms 16MB Cache UltraDMA 100/ATA 5 HD" ?????
2-Check and be sure a good bootable backup of boot drive exists on the External drive.
3-Shut down and physically install the new drive, discard old drive, plugging it into the same place the old one was in. (I guess this is right, but not real sure about this, any jumpers to move/check ??? , ) any other possibilities here ?
Now the variables/my best guesses :
4.a ) Power On, Startup use the (C key), and boot with my Tiger Install disk, and install a fresh Tiger OSX 10.4.xxx system onto the new drive.
QUESTION; Not real sure how to get this updated to 10.4.11 yet, but I think there's a "Combo" that will bring it right up to 10.4.11, but I'll need my internet connection for that.
Perhaps boot with the clone/external and download the update file to disk and install it that way ??? Definitely need some help with this .
4.b ) I could just copy/Clone in reverse from External to the new drive (I should think a clean install would be better here as to not keep any system flaws from my existing system, including that messy stuff that the latest security updates introduced. But, this could work, right ? Perhaps not ? I think I would really like to have a New Clean system as the Original HD may be weak/flawed.
4c ) Perhaps there's a function in Disk Utility that can help with doing all this, Restore? Archive ? whatever ?
OK. That's about where I am here. I'm not really a noobey, but I just never had to do all of this and want to be sure of a good plan before I get started, and don't want to overlook anything.
Thanks very much

Good News here, just to finish up.
I Got a FW external. Cloned boot drive to it (CCC 3.1.2). Did a archive & install on the external clone with Tiger DVD, and updated it to 10.4.11 + all misc updates. Fixed permissions between all phases. Deleted previous sys folder. Rebuild & optimize w/DiskWarrior. Pull old boot drive, install new WD 320 GB, connections were all "Cable-select", no master/slave stuff. Started up with tiger DVD and formated the seen new drive. Booted from external, cloned clean, archived/new SYS to new boot drive. Done.
Only a few small probs. with prefs. here and there, but all back and running fast & smooth and now I even have a regular backup plan to the external.

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