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I have had 2 RS's over a 5 year period and I have never had any issues, only thing i can think of is a battery replacement for both cars and a few bulbs here and there.
i know you have said you ruled out the battery, but i had the same problem 2 weeks ago, it was intermittent for about a month as you have stated with regards sometimes starting and sometimes not; Then eventually the battery gave up all together last weekend....new battery and problem solved for me.
it pops loudly when cold and then it much much more subtle when warmed up, as far as flames go i have no idea, it's hard to look at the exhaust end whilst driving....:rasp:
with de-cat technically both illegal yes.
I have heard a couple people on here saying that the Oreca system welds have started cracking due to them not having ample support on the back box.
pea-shooter exhaust would be my choice. they are a bit marmite thou.
http://www.cliosport.net/forum/showthread.php?573752-Ph1-Exclusive-H8teerrzz-Gunna-Hate!