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It's 4:15 AM over here, so no pix at this time, but if someone badgers me, I can show the results I obtained on the waste helmet I have here.. Additional badgering could result in full pics for tutorial.

Getting 1k sons heads is easy. You will need the following:
- loyalist marine helmets (csm are too fancy, though the plain non-horned ones will probably work)
- hobby saw
-hobby knife
-plastic card(to thickness of saw, or barely thicker)
- sharp pen
- liquid sculpting medium
- sculpting tool or dentist scraper
- files (recommended, but, optional)
-clippers( optional)

1.) grab yourself a head, fresh off the sprue. You will note the seam on the top of the helmet from the moulding process. Say hello to this guide line, and use the saw to cut into the helmet, almost down to roughly the mouth. (loyalist helmets have a band at the same height of the mouth piece, cut to there)
2.) test fit your plastic card. If it fits, great, move to next step. If not, grab your knife, and carefully slice off some of the inside material inside your cut, to make room until the plastic card fits. If you can get it in mmmmost of the way, that's fin. You can always shave the bottom of the plasticard, as that is easier than getting a perfect hole into the helmet.
3.) plasticaed fits? Put the head on. Gab your pen and draw out the outline of the headress. Use knife, and clippers to cut it out. Rounded files, and flat narrow files are useful for getting tricksy details in. If after cutting out, the headdress is not a perfect snug fit into the helmet slot, gently file away at the bottom of the headdress bit, until it slides in all the way. Use your judgement, you may need liquid sculpting medium to deal with ny gaps.
4.) glue the headdress in, and cut out two narrow strips to add stability, and the "essential detail" to make it look like the thousand sons head bit. Glue down the middle of either face. Side-to-side It mustn't lie flush with the marine's helmet forehead vent, liquid sculpty can deal with any gaps here. Add rivets to the two supporting bands to desire (or a channel down the middle... Or plain..... Whatever you prefer)
5.) apply a decent layer of liquid sculpting material to all faces of the headdress,and allow some time for the material to set. Add liquid medium to anywhere else you see gaps to make everything seam together.
6.) while the medium is pliable, use your sculpting tool/dental scraper to score the lines into the headdress. you will need to clean your blade/tool between scoring.
7.) doulble check the details, and apply more liquid medium or more scraping as desired
8. Once dry, GENTLY file away any rough or unwanted elements to he surface.

The fact that I could do this inebriated, coupled with the fact that I have no sculpting skill whatsoever at all, I am. Wry pleased withthe result I achieved. I know that with the costs going up, 1k sons may be a dieting breed on the tabletop, so I'm hoping I helped someone out here, either with getting their own 1k sons headdresses, or getting some variety in.

As an aside, the same method can be used to add horns, or even angel-wings to helmets, though, admittedly, horns and wings may need more skill for sculpting. The same thing could probably be used on terminators, cutting withthe saw instead into the torso, though,with all of the extra rims and ornamentation on CSM terminators,I fail to see the need....

Enjoy!

Note: all spelling and grammatical errors due to. This thrice damned worthless piece of trash iPad. Real friends don't let friends buy overrated and overhyped pieces of trash!

That's really helpful for me ... However Have you got any pics?

I would also like to see a piccy But will definatly be trying this out when I get around to the 1k sons army I'm planning. I was looking at the scibor Egyptian head dresses and puppetswar heads etc, but will also consider this too

alright, I'll aim to get pictures up when I get home sometime tonight, I'll see about what I have to do to make it a good quality, and whether or not I will actually have to make another helmet, as this test was done on a botched conversion to see how it would work.

Alright. This is the best that I can do right now. no idea where the household macro lens is, so I can't get a detailed shot, though I think this shows the gist of it.

seeing as I'm going to be getting questions about the lightning.......

cut out a strip of THIN plasticard. Take a sharp hobby knife, score it and get sharp points, zigzagging back and forth along the length of the strip. make a few strips. light a candle, and holding the flat lightning/flamey bit pf plasticard, let it curl in the heat over the candle. alternate sides and exposures to heat, and you may need to do some manual folding with tools/hands to get desired effect. Refer to crummy paint image: grey outline shows original strip, black outline shows what's left after cutting. You will need to glue a few of the strips into the hand forking out in different directions to make it convincing.

All of my thousand sons have a very simple recipe for a great looking helmet for the automatons of tzeentch. First, assemble your model as normal, making sure to remove mold lines.
Then, when the model is ready for the next step, yank that helmet off and throw it back in your bit box, and stab a ragged hole where its neck used to be.
Paint as normal, with a chipped ring of metal around the hole and blue blending into white inside the cavity. Voila, robot marine truckin' forward with its head blown off and magic Bolter blazing.