Hello,
Rockers will get you 20hp (I've done a back to back before/after dyno test to prove this). Make sure you drive the car fairly hard for a few hundred miles and re-adjust them. Headers, and no cats should buy you another 20hp on top of this.
I think your tune may be conservative, similarly prepared cars to yours that we have done are making closer to 670whp, this is on 93 octane, and relatively cool weather (60-70 degrees) at sea level, corrected.
So first thing I would do is to try to find out where your knock is coming from, get rid of it, and add some more timing back in, this should be good for another 20-40 hp. Where are you running the crankcase vent hose? If your running this back into the intake this is likely the cause of your knock, dump it to a catch can. You could have carbon in the cylinders that are creating hot spots that are creating the knock too, maybe try some sort of cylinder decarboning spray? I'm sure your running colder plugs already.
All of the above, some 104 octane and a new vec 2 tune to take advantage of the better knock threshould should get you there without opening the motor....
Dave, Does the catch can divert the hot vapors away from the intake charge? if so that sounds like a great idea...00PROWLER