You should probably clarify something here. When you start a trip, you are at 100% but you seem to think you would start at 80%. That small difference and now you are at 550 miles with a one stop trip. That is a pretty long trip but everyone is different.
In the Model 3 world, we chose to spend $4k to go from 250 to 325. Partly because my Model S is a 70D and down to about 220. So the Model 3 was going to be our long range car. Especially with the much faster supercharging. We would not have paid another $4k to get to 400. (well maybe)
If we could assume higher pricing for the S and that a 400 miles S costs $75k, I think you would have buyers for a 500 mile S at $85k. I think that is fairly reasonable ask. You would still likely sell more 400 mile versions but the take rate would be reasonable. And then of course, the P would be the 500 mile battery and be that much faster.
There is a 200 pound weight difference between the 70D and 100D so I would predict that it could be done for another 200 pounds. Worked into a refresh and no suspension changes needed.
If I was planning a refresh, I would shoot to use 2170 and get the range to 500. I would also hope to keep overall weight the same. Personally, I would not need the 500 and would consider a "short" range option in the mid 300s.
Having lived with a 220 car and a 325 car for a combined 100k, I have very little use for a 325+ car. A use for sure but very little and not worth thousands.