[urq] 2-Piece Manifold

[racingiron at comcast.net]

I haven't driven my car much in the past year. Anyone who's heard it run lately can identify the distinct sound of exhaust gases successfully escaping their manifoldly confines. It has a two-piece manifold, but the leak is obviously coming from its vicinity. I pulled it last weekend to find the source... 



I found four obvious cracks: two on the underside, and two more in the dividers at the turbo end. I also found evidence of significant exhaust escaping around the #1 port and its predominantly AWOL gasket, and maybe a hint around #2 and #3 ports. We think at least one of the nuts on #1 wasn't as tight as it should've been. Due to the volume of the leak, I suspect the #1 port is the main source. Here are some pictures of the manifold in question: 

http://home.comcast.net/~racingiron/ExMan/manifold1.jpg 
http://home.comcast.net/~racingiron/ExMan/manifold3.jpg 
http://home.comcast.net/~racingiron/ExMan/manifold4.jpg 
http://home.comcast.net/~racingiron/ExMan/turbo1.jpg 
http://home.comcast.net/~racingiron/ExMan/turbo2.jpg 

Removal (with head in situ) wasn't fun, but better than I expected. Only two studs refused to be divorced from their nuts, preferring to separate from the head instead. Unfortunately, the lower #2 stud apparently harbored strong attraction for the head as well, retaining bits of it in about half the threads. My German cohort (with not insignificant MB surgical experience in the Fatherland) thinks I might be able to get away with a simple retap (or rather, chasing with 3 progressively aggressive taps), while I'm leaning towards a helicoil-type repair. The #2 location seems to lend itself to drill application with the airbox and turbo conveniently out of the way. 

So, my questions: 
- Fix or replace the manifold? The cracks in the collector seem unlikely to be easily repaired. How tough is it to find a good 2-piece replacement these days? 
- Advice on the lower #2 stud threads in the head? Tap? Helicoil? Time-sert? 
- Oh yeah, we snapped one of the brass barbs on the CIS intake dome. Is there an reasonable fix for this, or should I just cap that hole and put a tee on the second one? 

TIA, 
Eric R. 
'86 urq 
'92 urS 
'93 urS