(1) You ask me "when did we carry more than 9 DLs", but you start with 9 DLs but admit a 10th. To answer your question, in 2012 the Pats had 11 DLs on August 31 on their initial 53 man roster; in 2011 they had 10:
http://espn.go.com/blog/boston/new-england-patriots/post/_/id/4728508/resetting-the-53-man-roster
http://espn.go.com/boston/nfl/story/_/id/6928953/assessing-patriots-53-man-roster
(2) When has the final roster ever been set after initial cutdowns?
As of today I would probably keep Chandler Jones, Rob Ninkovich, Michael Buchanan and Zach Moore as "DEs" along with 6 DTs, as you discuss (Wilfork, Easley, Siliga, Jones, Worthy and Vellano), expecting that there will be a lot of moving guys around at different spots on the DL. But I also think there is a darn good chance of picking up another player in the next 2 weeks. There is clearly a need for another veteran presence, and for a DE.
Right now I think that 9 DLs, 5 LBs and 10 DBs (including STers) are very likely as a starting point. Whether there's room for another DL, LB or DB (not including Browner's 4 game suspension) will depend on BB's analysis of the offensive positions and who has the most to add to the final roster.
Zach Moore making the team is a shock to me, I had him as PS all along.