OK.... time for yet another update...
i didn't do much more after the last post, as we were heading off to the US shortly, and didn't have the cash to buy another gate, especially as i had a brand fricken new one that shouldn't have a problem...
we checked the gate again, it appears the 2 parts of the lower housing aren't quite round and aren't quite fixed in position, a mate of mine took it to his work in case he could fix the valve on his lathe, but it turned out that wasn't the problem (it looks like the valve is either bent or off centre in the chamber)
anyway, he set it up so the valve was central, i put it back on the car and put 20km's on it, only opening the gate maybe 5 times at most, and it rotated and started leaking badly again.
so, after that I made the call to the guys who did the pipework for me, and ordered a genuine Tial 44mm v-banded clamp, picked it up saturday morning, put it on the car last night and drove it to work this morning... no exhaust leaks, no problems with overheating yet, and the power steering worked properly for the first time in years...
The power steering issue is an interesting one... Local workshop C-Red did a heap of pipework for me, and made up my braided lines and in the process, they found my engine mounts were the wrong ones. These mounts have been in the car for years, since the previous owner had it, and other shops have worked on the car in that time and not picked up on it, as evidenced by the intake pipe that is now about an inch too short (this one was made when the previous owner had the car). The shorter mounts were causing the power steering lines to rub on the sump, which may have affected it's performance (my power steering failed several years ago, and despite a couple of attempts to fix it, mostly centering around replacing failed lines, it never came good). Anyway, while this didn't seem like it would fix the steering, it's the only thing thats been done to the car that had anything at all to do with the steering system, and now it's working perfectly...