Make second partition on the drive using Disk Utility and as long as you don't install to that partition, it will not get erased by an OS (re)install.
You should be able to live shrink your existing partition and create this new space at the end if the partition view of the disk.
I'm assuming you have nothing on the new disk and essentially want to mirror what is on the old disk to the new disk.
You can use the following command line, substituting the proper names for Source-Disk (old) and Destination-Disk (new).
rsync -xavH /Volumes/Source-Disk/ /Volumes/Destination-Disk/
Note: The slash at the end of each path has significance, so don't forget to include it when changing the name of Source-Disk (old) and Destination-Disk (new). Also, if there are spaces in them, make sure you either escape the spaces with a backslash \
or quote the pathnames, but not both.
Explanation of the options used:
-x, --one-file-system don't cross filesystem boundaries
-a, --archive archive mode; same as -rlptgoD (no -H)
-r, --recursive recurse into directories
-l, --links copy symlinks as symlinks
-p, --perms preserve permissions
-t, --times preserve times
-g, --group preserve group
-o, --owner preserve owner (super-user only)
-D same as --devices --specials
--devices preserve device files (super-user only)
--specials preserve special files
-v, --verbose increase verbosity
-H, --hard-links preserve hard links
Note: Because symlinks are being copied to the Destination-Disk volume the volume name of the Destination-Disk will need to be renamed identical to the Source-Disk, afterwards, for the links to files on the disk itself to track. See the SYMBOLIC LINKS section in the rsync
man page for additional options that can be used to modify how the symlinks can be treated.
Best Answer
Are there any data on the 160GB external? If yes back them up. Then format the drive in Exfat.