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Big enough to avoid shorts with your power connectors.

You'll get it right, just make sure you use enough bolts and tighten them each bit-by-bit in sequence. I connect up the hoses and put my finger over one's end and blow into the other to check for...

Sounds good to me, I used the spade connectors, they are a pain in the rear and corrode / slip / come off all the time. Stick with the bolts and protect everything you can with heat shrink tubing.

Cutting the gaskets is time consuming and I personally can't stand the job :)

However, I found things went much easier if I make some templates and use those to cut around. One for the outer size...