data in /var is typically just regular files, so it's not a scary thing to move. just create teh new partition with cfrdisk or such like, format with mke2fs or mkreiserfs and then mount it somewhere, e.g. /mnt/newvar. next just use "cp -Rv /var/ /mnt/newvar/" and sit back. once done, just update /etc/fstab to relfect the new location of the partition.
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