Is gasket matching intakes and cleaning up the casting flaws and what not worth the extra time?

Just curious.

Also I have 2.73 gears with a 700R and I am going to go to a 3.73 or higher. Is the 4.11 worth it considering I got the overdrive? It is a daily driver and will be commuting on the highway to work. I figured it up on a gear calculator and there is like 500 rpm difference at 70 mph in 4th gear.

Personally,I wouldn't waste my time cleaning up the intake.
There will be no measurable performance gain.

In regards to the gears,you current combo is like having a 3.42/TH350 combo in 1st gear

With 4.10's/700R4,your 1st gear will be like having 4.88/Th350,which is too much gear IMHO
I personally wouldn't use more than a 3.73 gear

I gained about 2 tenths in the quarter in my car swapping from 3.70's to 4.10's behind my 700R4. I don't quite understand why people select a rear gear based on the tranny's low gear ratio when you spend a whole lot more time in 2nd and 3rd than you do in 1st. When I swapped from 3.70's to 4.10's my 60' time remained relatively the same, but my e.t.'s dropped about 2 tenths.