Took it to very nice local shop, and despite having it for 3 days, and having to get the power steering and alternator bracket out of the way, were able to remove stuck stud, and put it all back together with new gaskets.
It is again, a measure quieter, but still has that old truck sound when I stomp on the gas. Leak from somewhere after the cat? or maybe the EGR itself? The tube to the manifold I know looked fine.
2002 Focus SE, auto, 2.0L SPI