So I am having a hard time seeing these rpm vs. prop slip numbers add up. They seem very incomparable when looking at our two setups.
FYI, I am using the mercury prop slip calculator. (Our gearcases have a 2.25:1 gear ratio) My prop is 17p
http://www.mercuryracing.com/prop-slip-calculator/
For what its worth, I have only confidently recorded my WOT GPS speed vs. tach readings. (I have verified my tach is working properly with an add on electronic tiny tach.)
With VERY heavy load (full bait tank, batteries, fishing gear, three people on board), trim tabs deployed I am running 5450 rpms at 35MPH. This yields a 10% prop slip. Beautiful slip numbers.
With 400 lbs. less load (empty bait tank) and same load otherwise, I am running 5600 rpms at 36MPH. Again, 10% slip.
With just me on board and no bait tank I am running 5700 rpms at 36.7MPH, 10% slip
With just me, no bait tank, half tank of fuel, trim tabs disengaged entirely, I am running 5850rpms at 37.5MPH. (Porpoising like crazy!!) and again, 10% prop slip.
I am running an aluminum prop with very little cup. (14.8 x 17)
Now, lets take your prop slip numbers into consideration.
First of all, an SS prop that has been cupped should bite MUCH better than my aluminum prop, and your slip should be LESS than it would be with a cheapie aluminum prop. It should also lug the motor down more, not less. If I put your prop on my motor, it would take my rpms WAY down.
Lets look at your rpms in the 5500-6000 range.......
At 5500 rpms, 19p prop, 36 MPH, your slip number is 18.
At 6000 rpms, 19p prop, 41 MPH, your slip is 15.
These slip numbers are not unheard of, but why when you are running a lighter load and a nicer prop on the same rig, are your slip numbers 50-80% higher than mine are??? I just do not see how that motor can spin a 19p prop up that fast with a boat this heavy.
Lets assume that your 20 year old tach is acting a little wonky, and see what your RPM numbers would be at the same GPS speed, with a 10% slip:
19p, 36mph, 10% slip yields 5000rpms at 12% slip it reads 5200 rpms (as compared to your tach reading of 5500).
19p, 41mph, 10% slip yields 5700rpms at 12% slip it yields 5800 rpms (as compared to your tach reading of 6000).
I hope to get some feedback from others here, but I really believe that your tach is not reading properly. Something just isnt adding up here............