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I am in the process of designing a E-BIAB setup and am kinda torn with kettle size. Attached is a link to a web based calculator to solve the question, " How much will it hold?" Additionally, it breaks down by vertical inches, how much a gallon of liquid will displace based on the dimensions of the specified kettle (cylinder). It helped me, hope someone else gets use out of it too.
http://www.1728.org/verttank.htm
The kettle size is definitely an issue with biab. I typically brew 5 gallon batches in my 44 quart kettle but since you 'mash' in the kettle there are some recipes I have to downsize because the kettle is not big enough.
I use
http://www.rackers.org/calcs.shtml to figure the max size I can brew. Keep in mind that the basket, if used, and element take up a bit of the overall volume.
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