VDCRUISER,
I understand. I think the intercooler would make a pretty big difference. You'll lose approx. 1lb. of boost through pressure drop, so your 11lb setup will go to 10, yet more air will be in the cylinder because of it being denser. So, I think you'll be able to take the 10 intercooled with 91 octane. The reason the head gaskets are taking a beating is because it's detonating, which is almost 20 times the cylinder pressure of the normal combustion pressure. I would aslo check that you have 15lbs. of block pressure, operating water temp around 100 at WOT.
NOt sure what intake you have, but typically speaking, an intake change does very little in a forced induction motor. Aluminum heads will certainly help, probably a set of Dart 355's or Brodix -3's. This will probably be your best upgrade. Will be able to run 1.5-2lbs. more boost than with cast iron or less octane.
No matter what anybody says, it's harder than people think to make a true 1000hp with a roots blower, especially without aluminum heads, so thats what I would change first, then the camshaft depending on your current specs. The quad setup is the only next bet, can make another 100hp vs. your 1071, $5495 bolts right on your Superchiller.
Thanks,
Dustin