The base weld is cracked all the way around, and the exhaust leak is quite audible.

Hopefully that's why my fuel economy has been somewhat lower. Just noticed it an hour ago.

Heard it and then spotted it while trying to reset my IAC valve.

The EGR rim had been vibrating pretty bad (loudly) against the mounting bracket for that solenoid next to the ignition coil from time to time. I bent the bracket the other day, and noticed the entire EGR assembly seemed like it moved more than something welded to the header should have, but I didn't think to really check it completely at that time.

Anyway, tomorrow I'm going to remove a bunch of stuff and see if my dad can weld it.

Or if it's broke off completely (metal EGR tube and TB might be holding the whole thing in place. I don't know yet) and we can't weld all the way around it, I might just pull it off completely and have him weld a plug on it temporarily until I get another car and can then devote the downtime to pulling the header.

(should pull the entire engine and slap a 2.8 back in it for now, while checking for the mystery rattle, valve guide seals (burns oil on hot starts), and maybe put some 3500 heads on it)

*Pacesetter headers, in case anyone was wondering.

 

After two tries and much cussing and anger and such using a wire-feed, followed by a gas welder, we (mostly my dad) managed to seal it.

Thought we had it at first, but I could hear it through the plastic hose even though it wasn't enough to fan the flame with the torch test.

Second try with the gas welder was enough to seal it completely.