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3B Exhaust manifold



I finally got a few spare hours to attack my 3B project, which now, in the face of overwhelming advice, is a "refreshening" rather than a rebuild.  I dismantled the starboard side of the engine last night, generating the following questions:
 
1)  What should I divine from seeing so much carbon built up around the exhaust ports?  In the pre-electronics, carburated age in which I learned about cars, I'd simply say that this car simply had really light use and needed a couple stoplight drag races... There's gotta be what, 1mm or so of carbon caked up in there...
2)  That exhaust manifold really does appear to be an sub-optimal design.  Anyone with experience upgrading to the RS2 piece (or IA equivelant) I saw in Euro Car?  Any benefit to using it without concurrently upgrading turbo?  The manifold pictured in EC has four studs per outlet, the stock manifold has three.  What are my options here?
3)  I figure I'll replace all the studs, along with all the other fasteners on the engine.  Some look pretty grungy and I'd rather not break any (more) off.  Any advice about using heat on a steel stud screwed into an aluminium block?
4)  Folks who've done the 3B-into-CQ swap have found that the oil filter interferes with the AC compressor.  Solutions have been: a) remote locate the oil filter; b) swap compressor and alternator locations.  Anyone know whether a third solution might be use the S2 Oil filter bracket assembly?  It's a different part number from the US 200tq 3B, but looks the same on the fiche. 
5)  I've heard people on the list complain about melting through the rubber hose which runs behind the heatshield from the turbo to the ISV.  Mine is metal, except for the final 3".  Perhaps a change within the model year? 
 
As usual, TIA,
 
Brandon Hull
'91 CQ and a shrinking 3B