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So, I have been looking into making a traitor guard army and I am at a loss as to how to convert them. So far, I think I am going to use the Max Mini Combat Armor Torsos - http://www.maxmini.eu/store/index.php?main_page=product_info&products_id=129, and catachan arms and legs. I think that the bare arms on the armored chests would look good.

The problem is that I do not know what to use for the heads. I would like to use something from GW but I am worried about having to green stuff 60+ heads to make it look right. I found some good gas mask heads online but I am worried that I will not be able to take them to tournaments because if I use 3rd party heads and chests a large part of the model is not GW. If anyone know of any better heads I would love to hear it.

I would stay away from swapping the torso's, those are pretty core components of the GW line, and could run you more trouble than replacement heads.
Have you seen the wargames factory shocktroop heads??

If some of those are to your liking, I may actually be able to get a hold of some of them for you, as I have them. I already have 100 strong force and have about 6-8 srpues left of unused models (some of the heads have already been cut off and sold, and the ones I liked I kept) I will keep the bodies and make alternative auxilia to make the shock-troops stand head and shoulders apart from the line troopers.

I would urge you to keep the Cadians. Carve an eight-pinted star over the aquilla, or scar up the aquilla, and put the star on the other breast, helmet and pauldron. Many people just buy heads from Pig Iron to swap those out too, but I am going to guess you want a little more to distinguish.

If I could, I would also give each open-faced trooper a gasmask hanging off his helmet, attached, but not fastened everywhere. It should be relatively easy to make these masks from plasticard....

I was looking to avoid the pig iron heads, I like the way they look, it just seems to me that they would all look the same since they all have one of the ten heads.

I was playing around with some extra Cadians I have and they look good with their aquillas shaved off, I just don't know if they look "chaos-y" enough.

Since you seem willing to buy Maxmini products, did you look at the Fallen Legionnaire Heads or Evil Heads?

http://www.maxmini.eu/store/index.php?main_page=product_info&cPath=12&products_id=106

http://www.maxmini.eu/store/index.php?main_page=product_info&cPath=12&products_id=54

I saw those but I come back to the same problem, that if I use 3rd party heads and chests, half the mini is not GW so I am worried about not being able to take them to tournaments.

I really do like the Fallen Legionnaire and Gas Mask heads, so I might just pick a few up to mix in with the rest of the army.

What tournaments restrict you from having a model that not GW? I was under the impression that only tournaments run by GW had that actual rule and that they didn't run tournaments any more.

In my opinion you should just go for it with maxmini heads and torsos and make an army that looks great. Rule of cool tends to supersede anything like model composition anyway.

My friend made some cool traitor guard um mix and match a box of IG men and a box of marauders good times.

Other ideas just just go crazy after you start with some basic arm and leg and a crazy paint job and then you are set they will look good for sure.