Manifold suggestions

[gn1220]

I'm going to pull both exhaust manifolds in the near future to get the drivers side welded and milled and also get the turbo mounting flange milled. I've had the driver's side off before, it came off with no problems. I was wondering what, if anything, I can do to prevent bolts from breaking on the pass. side? I didn't break any on the driver's side but, with my luck, things won't go smoothly again.
Here's the plan so let me know if this sounds good:
1. Weld and mill driver's side to eliminate crack and gasket
2. Mill turbo mount flange on the manifold to eliminate RTV and leak (Don't need to mill flange that bolts to the head do I?) What about milling the turbo?
3. Mill D/P mounting flange to eliminate copper ATR gasket (Doesn't leak but I would like to get rid of the gasket, if it's possible)
4. What are opinions on Jet Hot? I know it looks good but will it help keep the under hood temps down? Will it help the manifold "live" longer? Anybody have this done and know what it costs?
Only want to do this one more time so I want to do it right. Please offer any suggestions you might have. TIA, Mike

 

[gn1220]

Any advice before I delete this?

 

[JToups386]

I'm surprised no-one has offered input here. We've all gone through this dilema before, to some degree.
As for the bolts, I'd say heavily spray them with penetrating oil/aerosol. Don't just use WD40, but rather, get some good PB Blaster or the likes, that is known for deep penetration. Let it soak in overnight, before you go to break them loose. I've never actually broken one off, but I'm sure it could happen, so anything you can do to chemically loosen them will help.

I don't know anyone who has actually JetHot coated their TR headers. I've thought about doing it, but it has never fit within my budget vs. priorities. I do know that you should not use header wrap on the stock ones though.

As for milling the surfaces, well, I'd say "go for it" as long as you do not go overboard on them. Don't thin the flange too much, as it will be more prone to warpage. Flattening them will obviously help seal things better, and especially if you can eliviate that copper ATR gasket that always distorts and eventually leaks too.
If your header-to-head flanges are not warped, then I wouldn't mess with them. I'd simply use the Fel-Pro gasket for those, as I've always had good results from it. It's also easy enough to replace when need be...
Hope that helps some.