Mike, I am not sure how the butterfly is attached. I guess I could take a look at mine and get an answer for you. It may be a bit later before I will get a chance to look.
On the other questions, it depends upon what position the butterfly is as to where to put the cold chisel. Be careful about this. The cold chisel is to be used like a small wedge. you need to determine which direction you want to start trying to get movement.
Chisel placement would be between the butterfly and the manifold inside wall. Whether you placed it at the top or the bottom, doesn't really matter that much. It would depend upon where the larger gap is. If the butterfly is frozen wide open, then the chisel won't work and isn't needed. If the butterfly is totally shut, you may not be able to get it started.
If you don't have a brass drift of the right size, you can use a piece of cold roll steel. I would NOT use a hardened punch, as you will definately mark up the butterfly. You could also cut a piece of 1/2" or 3/4" all thread, and grind a slight radius on the end that is going against the butterfly.
Last comment, and I am NOT trying to flame anyone here, but gray cast iron will NOT take heat shock (I am almost positive that these manifolds are Gray Iron). You heat up a piece of Grey cast, and then quench in cold water, it WILL crack or shatter. Remember, there are 4 different types of cast iron, and each one has different properties.
White Cast Iron
Characterized by the prevalence of carbides, impacting
•high compressive strength
•hardness
•good resistance to wear
Gray Cast Iron
Characterized with graphite in the microstructure, giving
•good machinability
•good resistance to wear and galling
Ductile Cast Iron
Gray iron with small amounts of magnesium and cesium which nodulates the graphite, resulting
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