Warmed over the 502 and landed at ~585hp and 575lb-ft torque. I have a 24p bravo and a 27p hydromotive for initial testing.

Any guesses or input on what else I might start looking for?

I realize the actual answer is on-water testing, but I'm not able to for a few weeks.

Bravo 26p might be the ticket. What RPMs do you want to spin at WOT?

we run a stock bravo 26 on a 25 foot thunder with xr 540 close to 800hp natural it works perfect we do twist it over 6500 its better to turn it up rather than over torque the drive

1.5 drive? the ratio makes a difference. The 24 Bravo isn't going to cut it. I'd start with the 27 hydro and see where it's at. My guess is you'll be on the limiter at around 80 and you'll need more considering the deadrise isn't 24 degrees

It's a 1.5 ratio drive and I'd like to keep the RPMs to 5500. The 27 is where Im going to begin.

What I’ve learned over the years is everything is a trade off with props. You find the ideal prop to run maximum mph w/ low fuel, cool air and no passengers on board and it sucks in real world conditions. You almost need a shootout prop and an ideal prop for everyday boating for how you use the boat. If you’re chasing a top speed prop chances are you won’t like it with passengers, a bunch of fuel and a few beers on board🤦🏻‍♂️