you mean bootorder of device channels, you still have to boot off of Master though? just select which ide cable it's on
ok when you install DOS onto a drive give it a partition of about 2gb it won't suport more depending on which version of dos, you will also want to install DOS-shell otherwise you'll be limited to creating files, coppying files changing dir, creating dir's and a few other kernal commands. Yes, you will have to back up your old files, can't you copy them to the other hard drive?
a few steps i know you'll have to do::
Crack out a 95 era Disk and boot up the PC (go to bios and make sure seek floppy is enabled and make sure floppy is the 1st boot drive)
When it's in type FDISK into the command
then you'll be giving various formatting options, go to delete partions and delete in the following order:-
Extended partitions
Logical Partitions
primary partitions (you may not have all of these but delete them all)
then go back to the first screen and make sure there are no partitions
select create partition and select primary DOS partition (or what ever it's called) when it asks you for size it will ask in MB so enter 2000 then you have a 2gig partition) now go find install instructions for DOS and DOS-shell when these are installed install XP make sure you select new partition on the XP install and don't remove the one you just created, also with the XP one it will ask you for format options, do the Quick format for NTFS unless you have a room to paint, it should at some point ask you for duel boot options, if it doesn't when you get into XP, right click mycomputer, properties, advanced startup and recover, and click edit then ask for help in here again so i can help with the settings