[tempest1964]

Well, there's a video online on how to stealth Pontiac heads. It wasn't too specific. I started with that and came up with this: I made a jig like he did. I used a router and a 2 flute carbide end mill with some WD-40 as a lubricant. I didn't have a set of 9770716 heads to use as a template to start, so I looked them up online and I made several sketches until I was satisfied and kinda winged it on the shape. Not to mention the casting on my KRE heads are a little different than the original 0716 heads. After I milled it, I have a de-scaler so while the jig was still on, i peened it with the de-scaler. This gave me the cast texture I wanted. Then I removed the jig and polished the freeze plug hole with a wire wheel. Finally, I filled the Kauffman lettering with liquid JB Weld and sanded down when it firmed up good. The numbers and letters were done after using a carbide dremel bit and the de-scaler. I used High temp. JB Weld for the numbers and letters. I had the best luck rolling it out in my bare fingers. Rubbing Alcohol and an old rag cleaned my hands really good.
At first I couldn't roll it out in thin rolls like I wanted to make the numbers/letters. I realized if it sat up for about 10 minutes after mixing it, I could control the diameter of the putty roll pretty good. Kinda like spaghetti strips. Then I had some drafting templates as guides for the numbers/letters. I used a round toothpick that I broke in half , using the full diameter end to nudge the strips to exactly how and where I wanted. I let it dry a couple of days and used my high heat gun to aid in the drying. I had read that JB can off gas and cause bubbles down the road. I degreased and taped off everything and 3 light coats of Pontiac blue. Below is a link to the video that I originally watched:
https://www.youtube.com/watch?v=0w4OlBbhNkY

[OCMDGTO]

Great thread here and it's a shame how many people in it are no longer active here. Here's a couple pics of mine, engine on the dyno has Edelbrock Ds and a T2 intake and the engine going into the car has KRE Ds and a T2

[Formulajones]

Originally Posted by tempest1964

Well, there's a video online on how to stealth Pontiac heads. It wasn't too specific. I started with that and came up with this: I made a jig like he did. I used a router and a 2 flute carbide end mill with some WD-40 as a lubricant. I didn't have a set of 9770716 heads to use as a template to start, so I looked them up online and I made several sketches until I was satisfied and kinda winged it on the shape. Not to mention the casting on my KRE heads are a little different than the original 0716 heads. After I milled it, I have a de-scaler so while the jig was still on, i peened it with the de-scaler. This gave me the cast texture I wanted. Then I removed the jig and polished the freeze plug hole with a wire wheel. Finally, I filled the Kauffman lettering with liquid JB Weld and sanded down when it firmed up good. The numbers and letters were done after using a carbide dremel bit and the de-scaler. I used High temp. JB Weld for the numbers and letters. I had the best luck rolling it out in my bare fingers. Rubbing Alcohol and an old rag cleaned my hands really good.
At first I couldn't roll it out in thin rolls like I wanted to make the numbers/letters. I realized if it sat up for about 10 minutes after mixing it, I could control the diameter of the putty roll pretty good. Kinda like spaghetti strips. Then I had some drafting templates as guides for the numbers/letters. I used a round toothpick that I broke in half , using the full diameter end to nudge the strips to exactly how and where I wanted. I let it dry a couple of days and used my high heat gun to aid in the drying. I had read that JB can off gas and cause bubbles down the road. I degreased and taped off everything and 3 light coats of Pontiac blue. Below is a link to the video that I originally watched:
https://www.youtube.com/watch?v=0w4OlBbhNkY

That's very similar to the same effort I was going to put into a set of heads to duplicate a stockish appearance. Nice job, lots of hours of work to get this done which is why I was happy to see a pretty good effort from Don to duplicate a stock appearing RAIV new head casting. That saves me time that I really don't have these days.