Wow,
You guys do like to make work for yourselfs!
The aluminum sounds like a heck of an idea, but expensive and extra work.
Mrfixit, you mean you've actually blown out permatex's rtv hi-temp sealer. Wow.
We use Ulta Gold RTV Hi-temp. on all our exhausts flanges, including the V-10's. On a good run our temps will hit 1125 on left and right tubes, even at these temps we have never blown out a seal.
As far as taking them apart, I haven't found a problem. Just grab an available edge and peal like a rubber band. If there is any residue left, when I re-do them I just "drag" a razor blade over the surface and go again.
That's my story and I'm sticking to it!
DV-- We need your support and attendance! Have you bought your raffle tickets?