I personally would not use something hard as you want it to give a little for packing etc - my first one (made with the Bosch trimmer guard) cracked so just re-made it to the exact same dimensions.
Original making part here:
http://www.rib.net/forum/f50/bombard...s-62326-7.html
I never throw anything away that might be useful and this time it was a piece cut from my old Disco front bumper!
This is for the 'L' and the splash guard rivetted on is the same piece of studded rubber flooring.
Rigid but flexible. New one below.
I have a 28mm block on the transom - tallest I could go without much modding as the engine clamps won't fit otherwise.
Would like to go higher but the major modding puts me off as does the fact it cavitates on really sharp turns with a 28mm block anyway.