You need to determine how fast your use air, if you want any buffer to handle problems on the bottom and if you want to have air for a safety stop. Tonight I was packing for a 90 ft dive tomorrow. I have a choice of 13 or 6 cu-ft tanks and I grabbed the small one because it is so small and I will not be in deco.
Personally I wouldn't bother investing in tanks that small, since the depths for which they would be useful emergency supplies would be so limited IMO. Using Lewis' figures from the article I cited, a 6cu ft tank has slightly more than enough capacity for a 5-minute safety stop at 15', and that's it. To my mind, we bordering on false-sense-of-security territory. On the other hand, you have a great deal more experience than I do, so YMMV.
The AL40 is ample for my max depth, and if I want redundancy on shallower dives it is extra-ample, plus carrying it keeps us in practice for deeper, more challenging dives. This makes it a blanket solution as I see it (short of proper doubles, of course). I have long since abandoned any aversion to lugging bulky gear around. The more you do it, the better you get.
To me it comes down to this: If I'm at 40m and I have a serious problem, I want to be sure that I have enough gas to ascend at an appropriate rate and do a full 5-minute stop, plus extra air in case something else goes wrong along the way. Beware the cascade...
Coming up hastily from max depth while my mind races to choose which corners I'm willing to cut on ascent is not an experience I ever want to have.
I'd love to know how you get that AL40 onto an airplane when you travel. . .
It's never been an issue; I haven't done a dive trip yet that involved more than a car ride and a ferry : )
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