According to the chart in the tccoa tech article, one of the oem tubular bars was a rear bar in 1.04 inches for the rear of the 91-96 NA V6 cars. In 90 the solid rear bar measured .98 inches, and in 97 it measured .94 inches, assuming again that the info from that chart is correct. The chart also says that the 92 V8 car was the sole year for a tubular .94 inch rear bar, which was preceded and succeeded by a solid bar of the same size. Is this information correct? If so, is there a measurable difference in handling between any of these rear sway bars that might be extrapolated to compare a tubular 1.25 bar to a solid 1.25 or 1 3/8?
I'll admit that I'm no engineer, so this project would be solely a venture based on experimentation and guesswork. I picked the 1.25 inch diameter because it's the largest pipe this particular builder can bend, it's relatively close to my current 1 3/8 bar, and there are 1.25-inch sway bar bushings easily available. Whichever size tubing might actually work best, there still needs to be a bushing of a corresponding size available.
And again, the wall size is critical. Does anyone know the wall thickness of the OEM tubular bars, or the type of steel they're made from?