Hi Frank,
I was thinking along those lines. I did try to do a brazing repair; but just could not get the head up to a hot enough temp. So, word to the wise, don't think of trying a simple propane tank and aluminum rod is going to work.
I had considered shopping the welding and surfacing job. But then I would still be left with the fact that the head would be thinner. After my CH repair last year, I kept to the Elring (gasket makers) recommended torque of 90Nm (about 66+ftllbs). I have not changed any of the head bolts. So I don't know how much "over"torque they can tolerate without breaking (I would truly want to avoid that). That's why my mind wandered to the used of a custom copper gasket.
If I could be reasonably assured that the head bolts could take the extra torque presumably needed to compensate for the thinner head after the weld-and-shave approach, then this would be the most economical and quickest fix.
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Currently enjoying:
1967 250S - all manual with 4-spd on floor-- my Nifty 250
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