Thanks for the suggestions, it's given me the oppertunity to post something you wouldn't normally read....
After attempting many of the suggestions here (or the ones that I had the means to try) Here are the official results of those experiements:

Its broke off below the surface.
It's a 5 bolt flange....

if it leaks i'll fix it, but until then

4 out of 5 bolts mounted flush, with a gasket and not leaking ain't bad.

Acctually mounted the downpipe onto the housing BEFORE installing back in the car just to make sure it was tight.


Perhaps something not many self-respecting mechanics would admit out loud but then again it's my car and not a customers so I have that option right?

Besides...this is HMT......if your willing to use PVC pipe to hook up an intercooler, then i know damn well your willing to leave out a bolt if you have to.

 

And who cares, a little raspy exhaust noise... some carbon monoxide fumes... ---- it, its the DP.

 

Wouldn't a leak at the point cause problems with O2 seeping into the exhaust and causing issues with WB or NB readings? Just curious.

 

Heat it up, douse it with water, the hit it with a punch. It should explode. Make sure you have a safety sheild on.

 

I'm rocking mine with 4 outta 5 cause I got tired of drilling out broken bolts and retapping. Having to rip the whole mani off to get to the turbo bolts so I could pull it off and put the hotside in a vise, then putting it all back on, not even mentioning oil lines and wastegate just cause i needed the downpipe out of the way for 5 minutes really started to **** me off

 

not leaking and not likely to,

 

leave it in their and weld a V-band onto the exhaust housing.

 

Thats a good idea!

 

Actually, that doesn't sound too bad.