since starting this thread I've learned a lot... so to try and answer you questions I'll just go in order...
1. from my understanding yes, as for this mesh plate I think you are talking about the baffles and I would leave those in or a lot of oil could escape. I plan on threading those exact...
It looks like he doesn't have a heat shield.... also maybe your cats are getting clogged too? wouldn't clogged cats make the turbo work harder due to back pressure?
It happens, old age and weak material.... it was bound to happen. adding the Y pipe just allowed them to spin faster which is what could have help done them in.
From my understanding the stock gaskets are fine to reuse, I've seen a few places talking about doing such a thing. I guess the important thing would be to inspect it and make sure it's in good shape and running order first.
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