Welcome aboard Welshman!!!
hijacking a 4 year old thread is somewhat frowned upon. I've moved this to a new thread of your very own.
Prop Size has nothing to do with heat. If it's hot on one side, it is constricted and the entire system is going to be impacted. As MMWJR stated, it's time to replace the manifolds and risers.
As for the prop, it is a combination of size and pitch.
1) Get the boat up to Wide Open Throttle (WOT). Make sure its properly trimmed and tabbed, and relatively smooth water.
2) Verify whether the rpm's are within the max range for the engine. (typically around 4400-04800). If your rpms are over, then you are under propped. If the are under, then you are over propped. This is usually dictated by Pitch.
Use the Mercury Prop Selector on their website.
Finally, use the SEARCH feature on this site. You will find hundreds of threads on the re-propping topic. Read through them and you'll find links, good advice and a common thread in all of them.
Best of luck.
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