TD,
I admit I hate to build a green that might give a super problems, although having problems due to over play for greens size might be considered a good problem to have these days. However, its also a problem to build too big, simply for the initial construction AND long term maintenance budget as you note. If a typical superintended built a green, it would probably be almost all flat and no more than 6500 SF.
My idea is based on total play, the tree cover and air movement of the particular site and the turf type - the combination of which should tell me how many levelish areas the superintendent might reasonably need to move the pin around. I find myself building smaller greens - and tees! - these days, presuming more like 30,000 rounds rather than 45,000.
RTJ wrote of having 4 or 6 pin spots in the 40's. Hurdzan writes of 21 pin spots in the 90's, based on the number of days it takes for a typical hole location to recover. Most superintendents I talk to would say you can cut the 21 days depending on how agressive your maintenance practices are, in all but the off season.
The problem is, if a superintendent won't or can't budgetarily aggressively maintain his greens to help them recover, I am not sure that extra pin spots are going to help him make the green look better. I also used to do bigger greens in shade, but also found that they either have the air movement they need or they don't - kind of like not being able to be a "little pregnant." Now, I just clear the trees.
Would you care to flesh out what you consider "bigger than it needs to be" for us?