I wrote up my complete 235 rebuild
HERE Unless you have (and can PROPERLY USE) a set of mic's then take it to the shop for the basic clean/inspect/flux. crenwelge missed A LOT of important steps like journal wear/out of round (no way to cheap that out... need to mic them) and maganflux for stress cracks that are not near the water jacket (like the cylinder wall, studs holes, bearing caps)and knurling a $5 valve guide?? Who does that on a rebuild?
I used clegg for a master kit and I was quite happy with it. My total rebuild was just under $1500 (parts and shop). Add in another $200 for misc parts (dist rebuild, fuel pump, vacuum advance/line), paint, misc. a DIY rebuild should be less than $1800-$2000. If you just do a top/bottom end then less than $1k on a known good motor is doable. Since I didn't know the history of the motor, I consider it a good investment to pay up front for a rebuild.
I did get semi ripped off on cam bearings.. I had the shop order them and while the price for the bearings was the same as I would have paid, the $15 UPS shipping doubled the price. A walk to the local FLAPs would have saved me some money.
