Is there a certain thickness or size I should be looking for
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I like 2" x 2", that seems to be the least bulky in appearance and when working around the area. Also, some boats have very narrow stringer-to-stringer widths. It may be necessary to clearance around the starter. A 2" wide rail gives you that much more room.
For most pleasure boats and all drag boats, over the last 5 or so years, I have run all 2" x 2" x 3/16" structural aluminum angle. Especially after it is slotted, the weight seems to go to near nothing.
Comp Jet boats and boats that will be run hard in rough water, I made rails from 2" x 2" x 1/4" structural angle. I would never want the engine to come loose, that would be the worst thing imaginable.
On that note, I want to bring up fasteners. I use 3/8" minimum through the motor plates, rails, and pillow blocks at the four corners. After seeing an engine that had come out when a Daytona hit the beach at full-speed, I'm even thinking 7/16" or 1/2" bolts. Make sure that you use lock nuts and that three threads protrude past the end of the lock nut. If the threads are flush with the end of the lock nut, the lock nuts will auto-eject. For the bolts through the stringers, I run five 5/16" or 3/8" bolts on each side, for the reasons listed above.
Be advised that the typical stainless steel bolts that are sold at hardware stores are GRADE 2!!!
