SR20's SUCK, recurring leak

[towlie]

Okay so, I've had my s13 blacktop SR for about 5 months with most of them being problem free daily driving. Recently I thought I had developed a nasty exhaust leak by scraping a hole in the down pipe when I noticed a terrible lawnmower sound.

Surprised to not find a massive gaping hole in the DP (only dented) I popped the hood and found the problem, scraping the downpipe must have blown out the turbo to manifold seal, I could feel exhaust leaking out.

I retired the car from dd duties and yanked the turbo out. The turbo to manifold gasket was so had I could wiggle the turbo with my hands and there was literally only half a gasket remaining.

Replaced/installed:

Complete OEM t25 gasket kit
S15 multi-layer manifold gasket
PBM cobra downpipe to prevent future scraping
Aftermarket turbo manifold
FRSport AN turbo line kit
CS BMC heat shield

The t25 had no shaft play and everything was cleaned/inspected before re-installation.

Stoked I hadnt broken anything removing it, everything was installed and I fired it, only to find the annoying fart sound still remains and it still leaks in the same place.

WTF?!

Could the t25 be blown even with no shaft play? Did I forget to replace anything? Maybe over/under tightened a bolt somewhere (no torque wrench everything was tightened till it could tightened no more)? I'm totally stumped, any help would be awesome!