Curly,
Here's my original sketch. Due to material availability we changed from 1/4" AL to 1/8" SS. I also wanted white oak, but couldn't find any. The only somewhat critical dimension is the 14.5" inside dimension for the sides, but even then it has some give. The actual dimension of the flat stock was slightly different than my sketch due to the bending. I let the guys here that bend metal for a living do their thing, but again, the dimensions aren't that critical.
The 1/4" flat head screws are counter-sunk into the wood for looks, but you could just bolt it if you wanted to.
I made the mounting a little too vertical, if I should have let it under cut just a little. Then again the motor just makes it down to vertical, so I'm going to leave well enough alone. I do have to cut away a bit of the original mounting surface so "secondary tiller" doesn't hit it when tilted.
The Suzuki 9.9HT is really a 15hp power head, so I can't imagine anyone would need more extension, but other motors might let you get away with a bit less.
One more thing, I'll have to come up with a new nav light for the stern or always have the motor down at night.
