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18% OD, E85, Intake, Headers & Tune should be 650-675 RWHP. Even more if porting is involved. I am not sure how you got 610-620 on a Pulley, E85, intake, Headers and tune. That seems to point to high heat, low reading dyno (Mustang), or (Unlikely) awful tuning.
A blower swap is obviously the answer for more power out of the LT4. IMO the route I'd go would be ProCharger if you wanted BIG power and a Whipple for everything else. I believe ZL1 Tommy is basically showing the outer limits of the Whipple on the LT4 with Heads/Cam/E85/Meth/Headers and he's running 922 RWHP. A Whipple on an otherwise stock engine is probably worth 100 RWHP I'd bet. Spin it a bit more, maybe 150 RWHP.
Vengeance has turned out Z06s (Lt4) with ProCharger conversion running anywhere from 800 RWHP on otherwise stock engines to 1100 RWHP on full builds. I'm sure the only thing holding them back there was the internals of the LT4.
I'll give a very rough outline of what the options are:
600-700 RWHP - Stock blower, just turn it up a little bit
700-800 RWHP - Stock blower and Heads/Cam/FBO OR Blower Swap on stock engine
800-900 RWHP - Stock blower Heads/Cam/FBO/Nitrous or Blower Swap on Heads/Cam Engine
900-1000 RWHP - Stock Blower Heads/Cam/FBO/200 Shot or Blower swap on Heads/Cam with more E85/Meth etc.
1000+ RWHP - ProCharger (Or other large centri style blower) or Turbos.
You're really up against an octane wall with anything over the 600-700 HP range. E85 helps. Meth helps. People who run away from using either end up limited at the mid 600 wheel range. What you'll notice is that the amount of power a blower swap will add (Lets say 100 RWHP) is the same number maintained across the board as you add mods to either setup.
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