Didn't you use to have pics of your bars on your site? Have you had good luck with the Johnny Joints? I remember seeing your bars a while back and thinking that they looked great!!
Our new site will be done this month. It will have new pictures, online store, etc. We have pretty much disabled the current site.
See attached....best i can find at the moment...my pics are spread out everywhere. But nearly identical to yours. My flex joints just have a threaded body, that you can adjust the 'preload' of the inner ball, where it looks like you have the snap-ring style.
Farmboy, are you also bigreen?
Yes, good to see you over here as well.
Or rather than just throwing more material at it, get smart and do something like in wicked's picture. That traction bar design works better as well.
A triangulated bar isnt going to be ideal in all situations. In many areas it will be best (like crawling, articulation, lots of wheel travel, etc). However, keep in mind the bending forces (due to the attempted rotation of the axle tube) those bars will see directly in the middle of the tubes, or where ever they meet into one. The upward force is enough to justify pretty large materials (even larger than a single bar in compression), thus becoming more expensive and heavier (and you already have to double the tube quantity).
Undersized material...and poor design (lower bar pushing up on top bar):
http://competitiondiesel.com/forums/showthread.php?t=28532
This, and triangulated pushes up on the framerail slightly (granted, not much, as its at the end of a very long lever arm), leaving the forward pressure to still be exerted through the blocks/leafs ....whereas the single bar pushes forward on the framerail; downfall being that the leafs can pull back and try to flatten. Single bars will actually work better with a flatter spring and bigger block, as it uses the leaf at a top link, and the block as vertical separation. More vertical separation = less pinion angle change.
My price difference on seamless SCH80 and 2"x.25" DOM is slightly more than the $5/ft you were quoted.