It would be quite possible for someone to make a rebuild kit by designing brass bushes/inserts and replacement butterfly's etc.
On a BMW diesel which suffers from failed butterfly's dropping into the engine, a set of blanking plates used to cost £100. Now down to £8 each. You may note the manufacturer of the failed swirl flaps is Pierburg!(same as the 150bhp 1.9)
http://www.pmwltd.co.uk/?page_id=155
Trouble is now that the manifold is down to £134 it probably would not be cost effective. Also it appears* that the later modified manifold design does not suffer the seized butterfly's like the old one.
An option would be to DIY blank off the spindle holes (drill and tap for BSP taper plugs?)and leave the ports permanently open - this would leave the full performance at WOT (wide open throttle) but would be very flat until the turbo cut in (just like with a failed manifold!).
It is such a pain to remove the manifold to experiment most decide to spend the cash on a new one.......
If the manifold was £500 it would be a different story
*fingers crossed it is still relatively early days....
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