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Not worth the time and effort, especially since you can get brand new aluminum heads that weigh less and flow better for about $900 from 440Source. Most amateur head porters just end up hurting flow anyway.

Are you talking about something like this: http://www.jegs.com/i/Mopar%20Performance/312/P4876785/10002/-1?CT=999. Looks like those are $1,700 a pair for bare heads. Have you looked in to RHS Indy X heads?

More cubic inches almost always equals more torque which is what you'll feel on the street. Weight difference between the two I would say is minimal.

I'm getting ready to add some baffles to my motorhome 440 oil pan, so I thought I would bring this old thread back up to see if anybody has some pictures.

When I had that trouble with my Demon, it turned out to be because of timing and mixture screws. I didn't have enough initial timing and mixture screws were in too far. A few simple adjustments and it takes off really well now. Your initial timing should probably be somewhere around 16-18...