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HAve you been checking the torque on the bolts every once in a while? They tend to back out on there own, and if they do and you don't catch it, then a blown gasket can be the result.
I too have never used a header gasket. The first set of headers I bought a buddy of mine tossed me some fell pro manifold gaskets, and they lasted 2 years....untill I pulled the heads. Then on the GMC, I think I had one side on there for 3 years...can't remember if I ever did pull the passenger side one, I know I did on the drivers side when I pulled the tranny to install a converter.
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