I tried the prop recommendation from the Evinrude dealer (Cyclone 4x14.5x15). Unfortunately that isn't going to do it for me.... Seems like my 2520 is happiest with a 3 blade.
So far:
Cyclone 4x14.5x17
WOT: 39mph, rpms 5200 (too low)
At cruise (25mph) the gas burn was around 1.5, but on a 70mile day I used 60 gallons of fuel...not acceptable. Also she didn't want to stabilize down around 4000rpm, and wanted to be at 4500. It was either too fast or too slow.
Cyclone 4x14.5x15
WOT: 38mph, rpms 6000 (just a bit high, 5700 recommended)
At cruise the gas burn is about 1.5mpg or slightly better, but there wasn't much of a speed range with this prop either. She wanted to be at 4700rpms and about 28mph which was way too fast for the situation. When I tried to run it slower at about 22mph it just wouldn't stay there, either would fall down to 4100rpms and 19....not holding plane well, or would jump up to 4700....
Quicksilver Thunderbolt 3x15.8x15
WOT: ~39mph, rpms 5650
Cruising fuel burn was best yet at around 2mpg
21mph = ~11gph
26mph = ~13gph
I'm going to see if the dealer will let my try a Rebel 3x14.5x17, and/or a 15 pitch, but for now I'm going to put my Quicksilver back on to collect more data.
KidFreediver: let me know if you have any new numbers with your prop testing.