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When I floor the car in 1st, the haldex will cut in but the car makes quite a noise... never happens in 2nd or any other gear. Its like a faint vibration through the front of the car as you floor it - it never happens when I give 1st some stick but not enough to sorta break traction.

Its quite distracting and sounds bad, but is it?

I get some funny noises sometimes but it's probably due to the turbo/exhaust ,are you running alot of torque?

Yep, 380NM of torque with the APR setup.

Might be to do with that,mine run's 460NM and it grumbles a bit too.