What's the best tooling for removing and shaping head material (Alloy), i want to have a go at porting a head (well copying actually).

Tungsten Carbide Bur, dont use a stone.
alloy will clog up a stone.

I've recently had a go at porting an alloy k-series head, and found that a 'Dremel' type tool and a set of these:-

Carbide burrs link

.......removed the bulk of the material pretty quick. Too quick if you use too high a speed, so ideally you want a variable speed 'dremel' so you can control the tool more easily. Then finished off with some of those sanding tubes (the type that fit on the rubber mandril), and some small flap wheels.

Takes a good bit of time and patience, but I was pretty happy with the end result.

Thank's for that, i thought clogging would be a problem, i shall order some bits from Ebay and experiment.

One of the flexible extensions that attach your drill and work like a dremel are quite good, the body is smaller than the dremel tool which is nifty.
Plenty of CRC/WD40 helps keep the tips from clogging.