well, SVT supercharged the Lightning with no ill effects so obviously the engine can handle a little boost. 380-400hp would be a reasonable number. and these transmissions are pretty bullet proof so they can handle it.
The Lightning 5.4 and the Raptor's 5.4 are WAY too different to make an assumption one will hold boost because the other did. The Lightning's bottom end was designed for boost; it is much stronger and built to support more power. The Raptor's 5.4 rotating assembly is basic (CHEAP) stuff that was never designed to hold much more power than what its factory rated output is. The Lightning has a forged crank, the Raptor's is a cast, the Lightning got heavy duty powdered forged rods, the Raptor's is very light duty powdered forged, the Lightning's pistons were forged, the Raptors are cast. The Lightning also had lower compression which prevents detonation when under psi, the Raptors compression isn't all that boost friendly for todays hit or miss fuel quality.
What decade are you living in? Thats not much of a supercharger if your only getting 60-80hp
the Lightning was a old 2 valve motor with a old Roush blower
The Lightning used the Eaton M112 (1.85L) blower unit. The current Roush kit also uses a M112 Eaton blower. Its the same damn blower unit from Eaton. Roush doesn't build any super charger units. It's FAR from efficient in comparison to todays standards. A Whipple, Kenne Bell or any twin screw design blower will be a much better choice. The 3v head does flow better than the old 2v but it doesn't matter. The stock Raptor 5.4 bottom end will never hold the power to benefit from the extra intake valve when boosted.
The 5.4L Triton engines are ok up to 22PSI on the standard "safe" side. They can go higher and take the pressure, but engine life is deminished. So if you get a Supercharger that averages around 10HP per 1PSI, you should make out alright. Most aftermarket "GOOD QUALITY" superchargers will allow you to go anywhere from 8PSI to 22PSI. So anywhere from 90HP increase to a possible 220HP+.
Maybe the GT500 5.4 is safe to 22psi but the truck 5.4 wouldn't last one dyno pull on 22psi. 10 psi is tops for the Raptor 5.4 motor and even then its a grenade with the pin already pulled. If you want the Raptor's 5.4 to last and be reliable run about 6psi.
Maybe trading for a 6.2 would be a better option. 100hp, and warrantied.