Did you deck the heads? Measure flat at least?
I just removed the heads from the engine today and discovered that they are in pretty rough shape. The cooling system must have been very acidic with the factory dex cool before I swapped it out as the heads are badly pitted anywhere they were exposed to coolant. This is why the heads were leaking coolant, the aluminum was eaten out to the point that they were letting the coolant out to atmosphere, and a small bit into the number 6 combustion chamber.
I have three options for repair:
1. Get some epoxy, fill the pitting, sand the heads on a flat surface until they are smooth again and slap em right back on. This is the el-cheapo option, heads are back on for about $650 bucks with new GM headgaskets and TTY head bolts.
2. Buy new heads and install. Heads are 1k shipped, and 650 for gaskets / head bolts, so $1650 to get the heads back on.
3. Buy a new long block with heads. All new blue printed and balanced rotating assembly with LBZ rods and coated pistons, brand new GM heads with injector pre-cups and a pre-lashed valve train, fitted to the block with ARP 4030 head studs and GM head gaskets. Engine comes with a new oil pump, and a 3 year 100k warantee. This engine will set me back 5k shipped.
Regardless of which way I go, at the very least I also have to install a new water pump and glow plugs (about 300 bucks for ACDelco stuff from Rock Auto). I've had issues with coolant flow the last little while (comes up to temp nicely, but I have no cabin heat unless I am above 1500 rpm), and when I tested the glow plugs only 2 were actually working

No wonder it started so poorly in the cold
I already have a nearly new set of GM injectors and high pressure hard lines, a new starter and a solid flywheel / south bend clutch & pressure plate for the engine which I put into it last time I worked on it less than 5k ago. Thats nearly 5k into the engine right there, so I am definitely fixing this thing.
What say CK5? Cheap out and hope it holds up for a while, fix it right with a new heads, or go all out and replace the whole thing? I just sold my ATV, so I have the means to do the long block replacement engine right now.
