In my opinion you will not see or feel much of a difference between the two over bores you mentioned. Generally the machine shop will recommend an overbore based on the existing condition of the block. If it has been bored before, how much that bore may have been, and how much it will take to "clean up" the bores at this time. Considerations may also be made as to availabliity of pistons you can get. As far as the intakes are concerned. My bet is that there would be little difference between the two intakes you mention. Your best returns for power would be to have the head worked over really well. There are certain heads that will out perform others simply by the nature of the design the manufacturer used with that head. There are the "848" heads for your 235 that are the sought after heads for more performance. If you can afford some porting/polishing work or oversized valves from the stock ones will give you better performance with your hotter cam. Of course you need to take carburation into consideration in the long run also. As to cast or aluminum intakes...generally only the after market intakes are aluminum and the stock OEM intakes are cast iron. After market intakes will be usually two or three carbs. Offenhauser, Fenton, Weiand are a few. There are others but they escape me currently and are more difficult to locate. The Offy intakes are most popular cause they are easier to locate. They are also re-popped type of intakes these days. Some of the others are originals from back in the day so harder to come by. I saw two at a swap just this last weekend here in KC. Both were Offy, one two carb and one three carb. Both older originals with one barrel carbs already on them. I am sure some other guys will add to this topic in good time. Oh and welcome to the bolt too! I hope to see you in Kansas City at the "All Truck Nationals" later on in the year. We had a bunch of "Stove Bolters" here last year and had a good time visiting and such. Make some plans to attend if you can.
