Hi
I had the same problem and had chats with various welders. You need to remove the manifold to for the simple fact that to do a half decent job it needs to go into an oven, welded, and put back in the oven and allowed to be slowly brought back down to normal temperature. Not only that you need to grind a slot into the crack otherwise the welder will end up chasing the weld all over the place and it won't stick properly. As if that isn't bad enough you need silver solder or similar weld rod, then it needs to be brazed over.
Thats to do a proper job, a crap job might just do it for a short while but you'll end up with the same problem sooner or later. Best advice is to get a stainless steel header and cat and away you go, plus you gain more horses into the bargain! New headers from the main dealer are about £300 and thats not including fitting it (not thats its a big job anyway). I'm sure others will point you in the right direction for header types and cost etc. The upshot of your problem is that its not really worth the hassle of welding it.
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