Hi Nuttyd,
I would still choose the Astroflight motors over 540, 800 or even 900 motors. The Astroflight motors are
powerful and efficient. www.astroflight.com/index.php
There are a bunch of ways to go about gear reduction. Some ways are loud and other ways are quiet and smooth. Before spending the money on gear reduction try running the boat direct first and see how it goes. If the motor gets hot quickly try smaller props until the motor is happy.
If you still decideto go with gear reduction use a 2:1 ratio then try larger props to increase performance. Anything greater than 2:1 will stifle performance and your boat will move like a tug boat. If gears like the brass metal gears that Dumas sellsare used, theboat will sound like a blender cruising across the water because of the metal on metal action. If a pulley is used and there is one on the motor and one on the shaft coupled by a belt the system will be much quieter.
Here is a place online that custom makes belt drives and everything you need tocreate a quiet gear reduction system for your boat if you decide to go that route..
www.sdp-si.com/
-Rich.