I'd make them as long as it needs to be on the boxed section of the frame and not be in the way of anything. On my truck, that is pretty much between the T Case and the crossmember that is under the fuel tank.
So what's the downfall to using Poly bushings at both ends? I'm not trying to be cheap by any means. But it's difficult to argue with the engineers at work who design semis and are suspension specialists.
why do they have to be dead on? I run hiems and have 1.5" of adjustability? If you measure and cut everything right there should be a problem? Oh and my bars are 82" from center to center, they are long and had to be bridged otherwise they would bend 1.5" OD .25" wall DOM.
Once I get time to build mine, they will be 2" square, .25" wall. I built all the suspension arms on my Jeep with the same tube and it's held up great.
The longer you go, thicker you need too.. My arms are going to be in the 5 foot range I think.
got any pics? I was planning 2" round just like normal. Then decided 2" square for strength. Now it looks like 2.5" square and 1/8 wall. I figured 3" would look a little odd. But if you have it. I'd like to see what it looks like.