why is there confusion over the size of

Another reason that I'm totally confused is that they are both citys so they should be the same size.

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That doesn't make any sense. Cities do vary is size, after all.

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Well, another way to look at it... Metroplex was built as Autobot City, whereas Fort Max was made out of a nebulon city.  Last I checked Autobots were inherently larger than nebulons.  Plus, Metroplex wasn't used all that often, while Fort Max was a major character in the japanese series.  This also would make sense as Metroplex would just be too large, and would cause major collateral damage when used, which is why he was used as a last resort.  Fort Max, if he was smaller, would have been able to be used much more frequently without the risk of larger collateral damage to those the autobots are trying to protect.  I know everyone wants Fort Max to be bigger just because he was the largest TF toy ever made, but common sense says that Fort Max would have been smaller than Metroplex.  The question would be how much smaller...

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he's only a nebulon city in the US version. There's also the possibility that the city was so huge that it was even bigger than Metroplex.

I tihnk the whole thing about him being smaller in Rebirth was probably an animation error. He's SUPPOSED to be bigger.