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I want to create a different header template for sales emails i.e. header sales instead of the default header. The template files are defined in locale/LANG/template/email/html/ simply creating a new template file headersales.html and referencing it in the new order email template as

  {{template config_path="design/email/headersales"}}

Doesn't work. Are the template names defined somewhere else?

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Paj,this should not work.

For this case you need to create handler and this handler will render the you phtml at local.xml at app/design/frontend/YOUR_PAackage/YOUR_template/layout

 <?xml version="1.0"?>
<layout version="0.1.0">
    <amit_customer_addhan>
        <block type="core/template" name="reviewreminder.email.items" template="Folderlocation/headersales.phtml" />
    </amit_customer_addhan>
</layout>

then on email html call this handler(locale/LANG/template/email/)

 {{layout handle="amit_customer_addhan" order=$order}}

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