Dealer for perfect fit replacements, after market if you have access to power tools.
Yes they have a knurled shank that's an interference fit in the hub you just hit them using a punch and hammer and they'll pop out.
One thing I did learn early on owning a Mk3 is with stock rotors uneven or excessive torque will deform the rotor hat and friction surfaces giving pedal pulsation.
Yes there is a huge pad cast inot the bottom of the block for the return, I'm not a big fan of using the pan as it's too low for my liking.
The return can't be in line with any of the Con Rods either as they will hamper the drain.
http://ij.supramania.com/assembly000.jpg
I use antiseize everytime I torque mine down ;)
They're subjected to high temps from the rotors so it's small insurance to keep the threads in good condition.
You turned up the boost so by the terms of the warranty there's little you can now do. (I'm guessing any number of things would in his eyes have voided the warranty anyway)
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