exhaust question - HELP!

OK here's the set up: I have a 1980 KZ1000 G1 classic. It has a 4-1 header that I took off to repaint. I put new copper crush gaskets on it and put it back together today and started it up.

Problem 1: it is really noisy up by the engine with lots of ticking and clicking. Much louder than before I took off the pipes. When I looked closer I saw that two or three of the "keeper" edges were bent/curled up. Because of this, they are not seated evenly in the finned flanges. I am guessing that this is keeping me from getting an even seal around the exhaust port. Is this the case? If so, I am in for a new set of keepers because I tried to flatten the flanges out and I couldn't.

Problem 2: the #2 flange was broken (split in 1/2). I got a used one from the local Kawie dealer. Then I had a little problem putting it on. Now I looked again today after I put it all together and the new one has a split in it. This is suggesting that my exhaust studs are bent on that cylinder and I overstressed it when I put it on. Does this sound right? Anyone else have this problem. I am guessing this is going to mean a new set of studs.

Sorry for the long post. I think I have the problems and solutions figured out, but I wanted to check with someone else who has been there before.

thanks all in advance.

Dale

yeah they can be a bit of a pain.you should be able to put a straight edge on the studs to tell if they are bent,be really carefull cranking down on the studs so you dont screw up the threads in the head.once you get a straight set of collars a rubber band is the best way i know to hold them on the pipe while you mount header.be sure to install new crush washers i always put the smooth side against the header tube.if you cantfind another flange let me know goodluck,happy wrenching!