OS X can go on an external drive and leave you with 100% internal of Windows only, if want.
Minimum can be in the 30GB range, depending on apps, data, etc and you want more than 15% free in any case, especially when using SSDs that don't like getting 90% full (and TRIM, GC need room to work with).
People do do 100% Linux and Windows on MBAir and MBPro models. Battery is shorter and run warmer.
Not sure what or why but maybe the Lion Recovery and other hidden partition structure 'got in the way.' Lion 10.7.0 did not properly work with Boot Camp and Boot Camp 4.0 drivers were another matter as well.
my experience is that going from OS X 10.5 to .6 and/or to .7 results in partition tables that are not "happy" and OS X does benefit from format with the new OS first and then install, and to not do an "upgrade in place" as many like to.
Doing a "clean install" and using Setup Assistant gets the user to where they were but with the new OS safer and better - just need to have their backups in good shape and current.