Re: Major diff. in wot rpm from alum. to SS prop
First of all, please post the Diameter of the various props. Diameter has an effect on rpm and slip. I am assuming they are the same, but are they?
As for max rpm on your rig, engine companies usually specify an optimum power range (most efficient power, best torque) which is often near the max rpm. MAX rpm is also usually dictated by motor longevity, reliability, and vibration reduction. IOW, go too high and your engine does not run as well or last as long. Your engine may be a de-rated version of a more powerful engine, but there might still be some limitations which would make it bad to exceed an rpm that is ok on the bigger engine. BTW, older engines are more likely to rely more on torque and less on RPM to achieve power. I would try to get a more definitive answer on what your max RPM may be. Merc should be able to do this. Have you tried online?
Comparing props is difficult because each manufacturer has design differences that go beyond dia & pitch. You are comparing too many variables. Assuming 5000 is your real max allowable rpm, find a prop that gives you that at WOT. Since you had power problems at low rpm, I would use aluminum, as this will flex a bit more and let the engine rev better.
I did the math 17 pitch should be my fastest prop.
Except that since you are comparing an AL vs a SS prop, the effective difference in pitch is greater that 2", as the Al wil flex more.
Your best bet may simply be to use an Al prop of the same diameter and 19" pitch.