Dave, I finally got to the shop. The front bar I ordered a 38.5x0.250x1.125 27 spline. Way to much for my truck. I'm limited to a 5" arm which will double the rate compared to a normal arm, so I'm stepping down to a 1"x.095x39 to get the lightest bar as a starting point. I thing they even make stepped bar in 3/4" with 1" ends.

The rear bar is no big deal. It's wider at 42" and I'm able to use 12" arms so I started at the 1.25x.095x42" giving me 200 lbs at 5 degrees of twist. I can step back to 1"x.095x42" and get down to 97 lbs.

At least I feel I have a decent starting point and I think found a set of used Long Acre corner scales close to me for $500. Then I can get my spring rates correct.

David