plugs for FI holes
#2
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Tap the holes & use screw in brass plugs. Could also size the holes to accommodate pressed in freeze plugs.
#4
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Could fill 'em in w/ an epoxy that can be removed w/ high heat. Splash zone marine epoxy has been successfully used in plastic manifold repairs. I'd say JB weld could work on an aluminum manifold. That's all I got short of making your own plugs using stock "o"-rings on a grooved rod w/ a cap on the end to make it look better.
#6
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Just get some expandable freeze plugs. You know the kind that you screw down the set screw to expand the rubber. That's what I would do. Maybe seal them with some grease when you put them in and check for vacuum leaks when done. Eric L