Well the job is done. The manifold was warped badly at the last cylinder. Shoot!
Removing the fender liner is a good idea. Helps with attaching the manifold to the downpipe and lining up the manifold.
I bought 25 of those rivets, used 5. Fastenall has the best price and I got them local! Got some spares if anyone needs some. You don't need a rivet gun to set them. I used the blade wrench for my circular saw and a pair of vice grips.
The new gasket has the typical high temp gasket material plus it has a metal backer that's riveted to the hi temp part.
I took one of the broken rear studs and threaded it in about 3 turns on the top. I also cut the head off one of the front studs and did the same there. I was able to hang the gasket on the studs and then do the same with the manifold. After putting a couple of the 4 center ones in I replaced my cut ones and completed the install. (would go much faster with an assistant here)
It is possible to do the job without gearwrenches! a 3/8" and a 1/4" can be used if you have deep and shallow sockets. Nonetheless, go buy the gear wrenches, $26 shipped from HF and you have them for later.
Time to do it? Too long as I took a break to go deer hunting and eat dinner.
Not the most fun job I've done but it's better than changing a rear main seal on a 4.0L !
My wife is happy now, maybe that's a good thing!