I often see people post stuff like "replace the head with Hornet, Warrior or others".

I already purchased several head sets from Hornet, Warrior, Ultracast and Legend, just waiting to be painted (oh the horror ) but I am uncertain how to do the actual switching of heads.

Most of the time the necks on the replacement heads fits very badly with the plastic figure.

Anybody got a godd step-by-step instruction on how to do this so the fit is invisible ?? Preferably with pictures

Most figure models have a solid neck area and sometimes even shaped to fit the recommended head from the box. This area must be drilled out to allow the replacement head to be set in the newly drilled hole. Thats why they usually come with a quite long neck. The advantage of the long neck is it allows one to rotate or adjust the head angle. If the figure has a head already, it obviously must be cut off first at the neck line.
I usually drill a small hole in the centre first and then increase the drill bit diameter to I get it almost perfect for the replacement head. Then carefully with a sharp knife clean away any excess plastic from the collar inside details. If the neck is still tight, some can be sanded/peeled from the neck of the new head also.
If you use a dremel or similar, the speed may be too fast and drilling will melt the plastic and stick to the bit ..take it easy if possible.
Sorry dont have pictures of this, but its pretty straight forward.

Jan,
I have always found the same problem having ruined loads of Hornet heads trying to carve them to replace the kit head. Then as Frank has told you Vinnie told me the drill a hole method and fantastic, 5 years of torment is finally over. Careful with the drilling and it all just slips together.

John

Thanks guys.

My new drill will come in handy