operabuffa once bubbled...
Thanks for everyones input.
Has anyone ever measured how much lift an empty Al 80 has at various depth and temperature?
The buoyancy of the tank doesn't change enough with depth or temperature to be noticed.
The tables will tell you that an AL 80 is about 4.1 to 4.4 pounds positive when empty. My experience is that an AL 80 with 500 psig of air, a first stage, a second stage, a short LP hose, a few feet of nylon rope, and two big boltsnaps is just positive enough to be a pain in the butt. I would expect some variation from tank to tank.
Your original question was about BC lift.
Here's what your BC needs to do:
When you get into the water, you are weighted to hold your shallowest stop with minimum air. Most agencies seem to be teaching 15 feet at 500psig.
When you get to depth, you are carrying more air than you're weighted for and your wetsuit isn't as buoyant as it was at 15 feet. The BC needs to be able to pick up the difference in both.
One fine day, I went to a pool, put my neoprene in a mesh bag and figured out how bouyant the stuff was at various depths. It turns out a Bare one piece 3/5, boots, gloves, and hood are about 16 pounds positive at the surface. Your outfit would be a bit more.
I lose a few pounds of that to get to 15 feet, so going to depth involves a loss of something like 10-12 pounds.
An 80 cubic foot tank weighs about 5 pounds more full than at 500psig, no matter what the tank is made of.
So, in theory, my BC should only need about 18 pounds of lift. According to the same computations, your BC should need about 30 pounds due to more neoprene.
What the manufacturers don't tell you is that the stated lift of a given BC assumes that the bladder will be able to expand unrestricted. In a jacket BC, there is a human body in the way. With backinflate, the tank may be in the way (maybe not).
In the real world, the 40-45 will probably serve you well. It allows for the discrepancies in BC lift, getting yourself a little higher out of the water at times, and the possibility you might want to use a really big tank like a 131.
There is a danger in going too big in that a stuck inflator will get more air in the bladder before you can stop it. That could make you look like Shamu jumping for the tourists. It could also embolize you or drive a boat keel through your skull. The people diving 100 pound lift BCs face that danger.