Agrajag, have you made it your mission in life to make my life more difficult?
You're right, I guess I'd better explain it more thoroughly.
1: it doesn't have to be a totally random process, if you're going for big buff warriors, naturally they're going to be larger, the same generalizations can be made for smaller units, and ofcourse, most units are going to be "average" sized, and estimates of size can lead to exact numbers quite easily. Size levels don't translate into centimeters and kilograms, they're categories as in general, but defined, ranges. Sizes outside the "average"
for a race would be used only in special circumstances, like specific heroes for instance. This is what is meant by "general advice".
2: if it's got hp, it's reminiscent of D&D, it's pretty unavoidable, and I've played D&D for long enough to know that it's not really very reminiscent, you're thinking levels, not size categories, and I've put a cap on hp.
3: mages are already quite powerful, and a simple ruling that mage commanders don't get double hp because with all the magical periphenalia they carry around, and with the stress caused by, and the concentration necessary for, combat magic, it negates the double hp commanders normally get, and solves that problem
4: you're right, recruitment/training probably would in many to most circumstances weed out the weak, depending on the specific type of unit (obviously more in ultra-elite units than in province defense militia), which is why you'd want a variety of units in the game to take advantages of different levels of training/quality. This process could be used to explain and increase the usefulness of some otherwise pretty redundant units currently present in the game.
5: I'm ok with hp as they are now, and already said so, this is just a little fun project for me, but some controlled randomness (knowing that a specific soldier is going to have between 7 and 9 hp or a dragon within 135-150) can be a good thing because then there's less complaining by people about how weak humans are in the game, because some humans would now be stronger than others, which is more realistic, and would make battles more realistic.