That's pretty sad. It won't cause a leak as the outside weld is tight but come on. It wouldn't be enough to drive me insane because stock manifolds are designed for 2.25" and the pipe is 2.5" but still.
I was never a fan of the BBK X pipe anyway. Something about the clam shell X design they use versus a traditional design made all my exhausts sound like pissed off bees at certain RPMs. To take it even further I was never a fan of X pipes in general. Too raspy, not as loud, and the tone wasn't deep enough for me.
I see you have kooks long tubes in the plans. What mid pipe and cat back are you pairing it with?
I have BBK ceramic coated long tubes with a BBK H pipe with Magnaflow metallic spun cats welded in attached to Borla Stingers. I have an O/R VRS X pipe designed for the long tubes and hated it. I put on the H pipe without cats and it was 100x better in my book but there was a trumpeting or farting noise at around 3k RPMS. Apparently this was normal for H pipes and flow through mufflers (non chambered). Threw in the cats (I went with the choice I did to get a reputable brand, metallic core to future proof it verus cermaic, smallest cat I could find and 200 cell count at a fair price) and I absolutely love it. It's a deep tone mixed with an exotic tone. Not sure if that makes 100% sense but it's the best I can describe it with. Also having no more exhaust fumes (I'd smell like exhaust after driving with the windows down and got out) was icing on the cake. I'll never run catless again.
I understand why people do it but to me the additional few ponies and 5-10% sound increase wasn't worth it. Please it's better for the environment.
It's almost like when you smoke. When you smoke you don't smell other smokers. But when you quit, you smell them easily. Now I can smell if a car has cats or not. I can only imagine what people behind me smelled.