OK, guys.
As far as I can tell, I've got some small exhaust leaks, both pre and post turbo(the DP V-band flange is causing me trouble)

Anyway, in the coming months, I'm thinking I want to solve it, permanently.

How does this plan sound:

1. Remove both exhaust manifolds, cut the exhaust flange flat. Banks up-pipe exhaust flange cut flat as well.
2. Use a 1/4" thick, solidly-welded exhaust flange to mate to it(like this: http://www.ebay.com/itm/Exhaust-Flange-Repair-converter-pipe-Replacement-Kit-Gasket-Hardware-FX8038-/171343050166?pt=Motors_Car_Truck_Parts_Accessories&hash=item27e4d775b6&vxp=mtr)
3. New crossover pipe, with a piece of flexi-tubing in the middle( http://www.ebay.com/itm/2-Exhaust-FLEX-PIPE-2-25-x-10-Heavy-Duty-Steel-10-Overall-Length-22510D-/161179054964?pt=Motors_Car_Truck_Parts_Accessories&hash=item2587053374&vxp=mtr )
4. Everything bolted down and gasketted with those crush-style exhaust gaskets.

I'm worried about making sure the flat flanges with gaskets can hold the pressure; I'm not sure what sort of drive PSI my TE06H turbo is getting; I'm also worried a bit about the flexi-coupling(but without ball flanges, I'm not sure how else to do this?)

On the downpipe side, I'm wondering about adding a ring of high-temp gasket material between the turbo and DP; Perhaps something like this? High Temperature Gasket Material | eBay


Any thoughts?

 

my thought is why try and reinvent the wheel when the kit is fantastically manufactured as is? did you try loosing up your dp down below to the exhaust and then snugging up the clamp up top?
what seems to be leaking with the cross over pipe? the section where the two meet down below in the middle? why,is it rusting out? if so,why not cut back on both sides to where it's solid and join them with a solid pipe? i gather the reason for not just calling banks to get the parts new is cost and your seeing what you can do on a budget.i dunno about the cross overs costs but i think the dp is around a Benjamin.did you already get prices? just curious what they ask for the cross overs,though mine are still both solid.