Hey James!

You should definitely check into rec.boats.cruising as Rick (RB) asks a
similar question.

Is the vessel only to sail from Greece to the US? Do you want to hang
about in the Caribbean afterwards or take her anywhere else?

In direct answer to your questions:

1=2E Anywhere between 30` and 50` is my personal opinion. If your
single-handing, smaller will be better - make that between 36=B4 and
42=B4. Remember, it will depend on the boat. A heavier built boat will
feel and handle differently than her lighter collegue.

2=2E Big matter of opinion here and you=B4ll find as many opinions as
there are boaters. Do you like maintenance? Are you a slob? Fiberglass
is low maintenance and repairable, but uses harsh chemicals and time.
Steel is strong but requires maintenance and constant paint. Aluminium
is fantastic but expensive and sensitive to electrical fields and
copper pennies (ok... galvanic corrosion). If it`s painted, you have
plenty of work to do. Aluminium doesn`t like paint. Ferrocement can be
surprisingly good IF built properly. Wood seems to be rarely considered
these days I think partly because it is difficult and expensive to get
good quality wood these days for boat building. If you plan to just
sail and then sell the boat, fiberglass will probably be your best
option.

3=2E Engine size depends completely on the vessel. Generally speaking,
designers have a suggested size that should be respected. Remember, a
larger engine can get you out of a tough spot, but will likely consume
more fuel, necessitating a larger fuel tank (or more jugs). Sails also
depend on the vessel. I would recommend, however, that if you have a
roller furling main, carry a storm trisail (ready fitted) as well. Not
just for the potential of a storm, but should for any reason you have a
problem with your main sail or system, you still have a sail to put up.
The Atlantic is not so huge, but it`s a real bummer when you have to
start putting up bedsheets because your sails have fallen apart from UV
damage.

Good luck!