Does it need to hold 5 quarts or what? I've been told 3 quarts for RD's. Also what type of material is being used for these pans? I'm thinking of using sheet aluminum.
Sheetsteel, Aluminum and fiberglass are used. I personally like using fiberglass because it's easy to modify, is light and is less likely to cause a crash if improperly designed with regards to clearance.
Regarding the capacity of the belly pan, I've been told that common sense will override anything; the RD engine only holds 1500cc's of oil. A three or five quart capacity would be overkill. Not to mention unsightly.
Common sense will defiitely be the determining factor but I do want tomake one point - while all 2-strokes do only hold a small amount of liquid in the bottom end they all carry a decent amount of fuel and some caryy water as well.... when you get to the point of making one, once it covers the bottom of the bike 5qts isn't really that hard to do. It's not a firm quantity for 2-strokes but I wouldn't go under 3...