Sorry, was in a bit of a rush, just trying to be polite so folks wouldn't respond to something I no longer needed a response to!
It turned out to be extremely simple:
1. Clone your Lion system to an external drive using SuperDuper. Or you can use Carbon Copy Cloner, I prefer SuperDuper because it preserves creation & modification dates on all files. I refer to these dates constantly. Come to think of it, I don't know if CCC will actually work here...
2. Shut down & boot off that external drive.
3. Wipe your old drive & format to one partition using Disk Utility off the external drive. This eliminates the restore partition Apple grabs from your drive.
- Launch Disk Utility
- Right-click on the Disk (not the partitions) and select “Erase”
- Select the default Mac OS Extended (Journaled) as the file system, and give the drive a name
- Click on “Erase” to completely format the drive – you will lose all data on the drive and all partitions
4. Restore Lion & all your system/user folders & files using SuperDuper off the external drive.
Viola! No restore drive, you've reclaimed all your space. SuperDuper does not copy the restore partition. Now you can add other OSes & not run up against the 4 partition rule so quickly.
This took me about 2 hours & was fairly easy. Recovered that huge partition on a small SSD in a MacBook Air - where space is expensive & at a premium. Works like a champ, too. YMMV. Good luck!