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~*Field Mouse*~ Lebanon, Oregon (92 Bonneville SSE) (Dark Polo Metallic Green) "Green Jelly" (Daily Driver) Silver Star Lows, Highs And Fogs What A Bright Idea...

Bottom line is that your crossover is probably cracked under the heat shield, and you probably also have cracks in the front manifold.

Nothing temporary will really work, and before attempting a repair, keep in mind they are low-grade stainless steel.

My best advice is to remove both manifolds and have them properly repaired. The best way to find leaks is to fill them with water and look for outside leaks. The small leaks can be VERY hard to see. Leaky manifolds do cause a loss in performance, as well. Once they're repaired, they'll be fine. I did my first set about 6 years ago, and haven't developed any cracks since, even though they run far hotter now.

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Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers

Yes it is a common problem. I had to do the same thing with the 94 Series 1.

Remove all the manifolds. Remove the heat shields. Cut off wheel works. Drill out the rivets.
Bring them in to a good welding shop and have them weld them up and re-weld the shields on. Use new rivets.

I couldn't believe how big the cracks were.

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2000 SSEi - SilverBullet - 78,000 kms, 4" "straight shot" custom headlight ram air inlet, TOGs, 1.9's, Lsd, 2.9-3.4"MPS 10-15 psi, Ported GenV, EGR eliminated, OR pushrods, oil volume kit, trani cooler & shift kit, Titanium retainers, 90 lb springs, 160 Stat, 42# injectors, Fuel pump voltage increase, Wideband O2, 3" to dual 2 1/2" Magnaflows, Snow Meth/water injection, after SC temp gauge, 255/50WR17, timing commander set 15-18*@WOT, 2 speed Fan over-ride, disabled DRL, Solid motor mount, Meziere Electric water pump, adjustable fuel pressure regulator, Drilled & slotted rotors/ceramics, GXP sway bars and STB, Upgraded and rebuilt transmission with ZZP 2500 rpm stall TC, Pioneer Bluetooth stereo with sub and 800 W amps, PB 13.5 quarter, (April 2014 car of the month)

Remember to suggest they bolt the flange down in all the bolt locations. That will prevent warpage to help the manifold seal to the head. But use a gasket anyway when you put it back on.

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WHITE WHINE - 1992 SSE Supercharged 236.26 ci (.040 Over) 15.090 at 90.2 MPH on old engine w/ slipping trans & melted O2 sensor - Gen 3 M62 and matching TB, Gen 2 Pully, Zillamotorsports Ported LIM, YT 1.72 Roller Rockers, SII FPR & Injectors, Hypertech Thermomaster chip w/ 160 Thermo, TransGo Shift Kit, Infinity/Pioneer Speakers & a 10" Alpine Type R Sub, all the watts, 140 amp Alternator, Ricepipe CAI w/ heatshield, Pilot Angel Eye Foglights, Clear Corners, '02 17" Chrome Bent 5's, Magnaflow F-Body Muffler and Hi-flo Cat, Ceramic Coated Ported Exhaust Manifolds, Fan Override, Monroe Reflex struts, red calipers
2009 G8 GT - Sport Red Metallic, loaded, SOLO Axlebacks, Rotofab Intake, Tuned, autodim mirror, removed intake manifold cover, HSV GTS triple gauge pod, two tone red-hot shifter and HSV SuperSport steering wheel, GXP rear sway bar and diffuser, 3.45 diff and various Camaro suspension bits, LED Taillights

If they have no way to bolt the flange firmly during welding, have them do one crack on the rear, then a crack on the front, then a crack on the crossover, etc. Let each piece cool before welding another spot. This technique AND clamping the head flanges down are preferred together.

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Click here for mod list for both cars
93 SSEi, 95 SLE (supercharged) 97 Buick LeSabre Limited
PontiacDad at WCBF '04: Cruise control? That's like surrendering!
Comprehensive guide to troubleshooting, rebuilding, and modifying Eaton Superchargers