Hmnnn, the more I stare at the PTE Not-Kato, the more I think all you need is a body swap for a smaller body size (again, if PTE is taller than TTB the skin tones are a pretty good match too!) and a bit of a mixture of DollyKim's advice and my own (if I do say so myself *coughs* ). I wouldn't quite go as far as carving out his hair since he already has a natural part like Kato does, but I would sand/dremel/shape it down into the slicked look Kato has and then use DollyKim's advice and carve in the smaller details like the suggestion of individual clumps of hair for realism's sake. The face may need a little touch up but for the most part he fits the Kato role pretty well in my opinion. I don't know that you want to be going for a Barbie (or Japanese Ken, no matter how pretty he is XD) head and the bother of a reroot, especially since they won't really look like a matching set, whereas right now they look pretty good together even as-is. I think shaping the hair to fit Kato's might make you like your PTE guy for Kato a little better.
OH! And as for outfits...what sort of outfits are you looking for? I know they wear their usual "costumes", which might be worth a custom project and hiring a seamstress for. (I can recommend a few, but one works only on ones she feels like doing, and the other few are really, really clogged up with orders, so you may have a month or two wait on your hands?)