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I need to make a few more runs, but I think the rattle is nearly all gone. After a few heat cycles, I think the flanges moved closer together on the passenger side. I can also confirm that if you have this problem, re-torquing the bolts after a couple hundred miles does help. I plan on retorquing again and that will hopefully fix it for good.
I suspect that some of these problems on aftermarket exhausts may be due to the gasket pocket machined in the flange not being exactly the same as the factory...the pocket may be a little undersized and the gasket has no where to go.
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