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It will be emissions/cat/lambda related.
The rattle noise does sound similar to strings of rubber hitting the rear arches as they're peeling off. Is it from the rear?
The ktec 182 championship ones will be 60.1mm so that they don't require spigot rings and are stamped for the series.
I'm guessing you'd need proof of being in the championship to get them at their discounted price.
Yeah i doubt the old one was tight enough/torqued really. Goes to show how much torque you can apply when using a torque wrench compared to using the 1/2" ratchet. Did it up with the ratchet and it felt tight, put the torque wrench on and got a few turns on it.