Yes your calculation is corect Im suprised your keeping your heads how much to modify them? I thought it was cheaper to just buy out of the box bolt ons not to mention wieght reduction and being able to go with a higher comp ratio how are you going to get 500 hp? Big cam and retune the ECM? I thought you couldnt go to big of cam lift because of sucking in water or can you go big lift and les duration what are your cam specs and comp ratio going to be
You can get high compression out of cast iron about as easy as aluminum. The plus on cast is it is more durable in a marine environment, even more so with open cooling. Unless your building something which requires more air flow then cast is the way to go. Compression builds by decreasing head gasket thickness. shaving the head, reducing deck height, piston volume and bore. Easiest way to build HP is increase compression but the other side is the cam.
Your previous post shows your using oval port heads instead of rectangular port, so your keeping air flow down. You could have gone with rectangular port heads and eased air flow. With remaping the ECM you could go with putting 502 heads on your 454.
My build should come in between 500 and 525HP (started as 415). The cam will be custom grind higher lift and less duration, and since I'm not running dry exhaust we cannot get to wild with duration so reversion should not be an issue. I'm going from a MEFI1 to MEFI3 ECM, intake top portion of runners cut down, fuel rail will be custom modified with return line to tank. Number 7 injector will be opened up and the VST will be changed out for cool fuel.