Gnomebrewer
Well-Known Member
As always, you have two intersecting slopes - one having to do with flavor and color improvements of minimizing headspace by reducing oxidation. The other with diminishing safety based on minimizing that headspace. Where the two slopes intersect is your sweet spot. Might be 1/4" for example - enough to minimize oxidation "enough" balanced against producing safe bottles "enough".
I personally wouldn't worry about the 'safety' aspect - wear gloves and glasses if you're worried about the breaking whilst being handled (once chilled the risk is all but eliminated anyway) - but I wouldn't want to lose a batch of beer to broken bottles! Bottle necks are approximately 17mm (diameter) so 1/4" is approximately 1.4mL (less than thermal expansion). Maybe go with 1/2". Or bottle at room temp.