What's the largest belt knife you'd comfortably EDC on your hip

Tough to say. Under the right circumstances, I would have no trouble edc'ing a 22" machete...

Under normal (urban) circumstances however, I prefer the 3.5"-5" range as my comfortable sweet spot.
 
My limit was ~6 inch blade (~11 inch overall). I carried an urban grudge of this size for months and do occasionally now. However, I found that a 4 inch blade seems to really be my preference currently.
 
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