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In general, I'd make it about the size of the 80, but remember that if you're outgrowing the drive now, you're going to definitely get a larger one. As such, giving it some more room to "plan for the future" is a good idea.
You definitely need to partition if you're going to store a backup and some archived data side by side.
Don't worry about the Sandbox for now: you don't sound like the kind of user who needs it, and it has nothing to do with archiving.
Please remember: the "archive" is something you're managing yourself. Move files there when you want to save them. Do not direct SD! at the archive volume!
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--Dave Nanian
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