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Mine are very noisy too, sounds like a lot of valve train noise. I think it's just the nature of the tubing. When the exhaust valve opens the pressure slams the thin walled tubing. With the manifolds, the thick cast iron quiets that sound.
Mine don't leak at all, and I just re-used the OE gaskets. If you used the OE gaskets and tightened according to the directions from the center out, I doubt yours are leaking. I know what you mean though, when I drive next to something I'd swear they are leaking, but I know mine are completely leak free.
The only thing I can think that might quiet it down would be some type of coating. Whatever the thickest header coating out there is, might quiet it down a bit. Maybe? I was thinking of trying Swain coating some day.
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