What size should I allow for strerror_r?

Having a sufficiently large static limit is probably good enough for all situations.
If you really need to get the entire error message, you can use the GNU version of strerror_r, or you can use the standard version
and poll it with successively larger buffers until you get what you need. For example,
you may use something like the code below.

#include <errno.h>
#include <stdio.h>
#include <stdlib.h>
#include <string.h>

/* Call strerror_r and get the full error message. Allocate memory for the
 * entire string with malloc. Return string. Caller must free string.
 * If malloc fails, return NULL.
 */
char *all_strerror(int n)
{
    char *s;
    size_t size;

    size = 1024;
    s = malloc(size);
    if (s == NULL)
        return NULL;

    while (strerror_r(n, s, size) == -1 && errno == ERANGE) {
        size *= 2;
        s = realloc(s, size);
        if (s == NULL)
            return NULL;
    }

    return s;
}

int main(int argc, char **argv)
{
    for (int i = 1; i < argc; ++i) {
        int n = atoi(argv[i]);
        char *s = all_strerror(n);
        printf("[%d]: %s\n", n, s);
        free(s);
    }

    return 0;
}