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So I haven't worked this out in detail but I am thinking of building out a force around two suit squads, shooty and assault. The assault suits maneuver to intercept the enemy while supported by the shooty suits. Meanwhile an outcast squad screens each suit squad. I'd spend any margin on flitters. Is this a sound theory?

I've not fought much against outcasts to know much other than they can die really fast and provide extra wounds for the cheap disruptor cannon and cheap order dice to help dice more often.

With the suits don't forget to add extra models help against the 1 pin per model break test that they're vulnerable to.

Personally, at 500 points I'd really leave the Assault Squad at home in favor of another Battle Squad. They cost exactly the same, but Ghar Battle Suits are Large, which means they can't Sprint and that they have additional penalties for moving through difficult terrain. Wich, in most cases, means that at 500 points you won't be assaulting unless your enemy wants to. Also, Battle Squads are still very scary on assault, as the can Firefight with their Scourer Cannons before the actual close combat.

Furthermore, Assault Squads swap the Battle Squad's Scourer Cannons, which are very, very good weapons, for Gouger guns, which are inaccurate (and Ghar are not very accurate to start with). They also can't shoot disruptor rounds, that are scary powerful.

At 500 points I'd also advice you to take minimum sized Ghar Battle Armor Squads. You want as many activations and targets as you can get, and at low points Ghar already are at a disadvantage in that regard.

OTOH, at 500 points Ghar can only field 4 units (2-3 Tactical and 1 Aux), so that limits you a lot in what to get, too. Personally I'd choose as a third unit an Outcast Squad with a Disruptor Cannon. That's another activation, Lugger guns can be nice at short range because they shoot a lot, and the Disruptor Cannon is another Disruptor gun, which is great. If you put them inside good cover (something that Ghar Battle suits can't benefit from, they end up being Res 6-7, which is actually somewhat decent.

That leaves you with 45 points to play with. Unfortunately, Plasma Amplifiers cost 30 points per unit, so you'll have to choose ^^.