You could have it welded, then re-machined.

 

I too would repair the one you have to re-accept the o-ring gaskets, but on the other hand I don’t see why you couldn’t use sheet type gaskets if you find that you run out of other feasible options.

 

The sheet gaskets are a good idea if I want to keep the port match as the port on the 245 TFS heads barely fit in the footprint of a stock LS1 gasket (which the kb manifold uses). Unless there is another application with a gasket of that type. Then I could have the grooves welded up then re machined for the larger o-ring type gaskets.

 

Look into Professional products gasket 52610 This might be the ticket your looking for.

Edit:
Also found Holly has something similar but for more money. Holley 108-117
Felpro 13123
Speed master PCE349.1019

You decide what might work... LOL

http://www.ebay.com/itm/Professional-Products-INTAKE-GASKET-SET-FOR-LS1-LS2-LS6-52610-/231693682872?hash=item35f20508b8&vxp=mtr

 

After following all the leads I had and coming up empty I have decided to attempt a repair. Thinking about the suggestions here and looking over the manifold here's my idea.... Fill the gasket grooves with a aluminum brazing rod such as Alumiweld, HTS-2000, etc, resurface the flange and use a sheet gasket such as the Felpro 13123. I plan to use a mapp gas torch and possibly my grill to keep the temp up while brazing. Going this route seems a little easier to do with my limited brazing skills and will also allow me to keep the port match between the heads and manifold. I am open to suggestions or tips on how to make the repair. From what I have read, you get one chance with these fluxless brazing rods as the material can't be welded with a tig afterwards if they repair doesn't hold.

Here are a few pics showing the damage a little clearer after removing the gaskets...

 

I would Not Braze it. I would have it Professionally welded Then file it down. If the brazing doesn't go as planned you might end up SOL...

 

Id take it to a machine shop and let a pro clean it up.

 

I will be having the grooves tig welded. I dropped it off with my welder just a while ago and may have it back tomorrow so I can work on it this weekend. I ordered the gaskets last night and should be here on Friday.
My plan is to clean up the ports where the weld will likely spill over at the thin damaged areas to regain the port match to the heads. Then I will use a sanding block with varying grits to slowly level the weld to the existing surface, checking with a straight edge as I go.

 

Cant deck it?

 

I could take it to the local cylinder head shop but he's pretty slow and this task seems simple enough since there is an existing surface to reference. Plus I have to clean up the ports where he had to build up the weld on the thin side.

However my welder is pretty quick. He called me this afternoon telling me it was done. I got there and it was still clamped to a large piece of iron channel to keep it from warping. I've got work to do now.