UPDATE: Finally got everything staged and did the swap over Thanksgiving. Took out the very tired, old 3-speed and column shifter and installed a Borg-Warner T-5 from an '86 S-10. Also replaced the OEM 3.9:1 ratio rearend with a 2.73 setup from an '87 Camaro.
My concerns going in, especially running the 235, were mirrored in your comments - I suspected I wouldn't have enough power in 5th gear to push the pickup into higher RPMs. After a 4-hour road trip, all suspicions were confirmed. I barely had enough power in 5th to maintain 75 mph, much less increase my speed. On hills/inclines, I would have to downshift to 4th for the needed torque. Of course, downhills were loads of fun, going faster than that old jalopy had ever been.
Concern #2 was my biggest fear, that the 235 would just be too weak out of the blocks. The original overall drive ratio in 1st gear was 11.47. With the T-5, the new overall 1st gear ratio is 10.26, and there is definitely an added load on my little 6-cylinder. But as long as I don't have tailgaters at stoplights, I am getting off the blocks just fine, but very much anticipating completing the rebuild of my '66 283ci.
I would appreciate any tips or tricks to squeeze moree hp and torque out of my 235.
JON