A sucker for punishment, I guess? Good.
I've never discussed my homebrewed panhard bar much. Most sane people just buy a preexisting bar from someone in the Mustang suspension business and save themselves lots of grief.
The aluminum panhard bar is 34" long and was sourced from one of the Circle track places (stockcar products if memory serves) and the rod ends (3/4" shank and thread) I bought from a local place that deals in bearings and such.
The chassis side bracket was fabricated from 3/4" steel pipe (yes, I said PIPE -- it's approx 1/8" wall thickness and measures roughly 1" OD), 3/16" steel plate stock as well as some 1/8" steel plate for gussests. I made a chalk sketch on the floor of my garage and used a combination of a hand conduit bender and slotting (welded up the slots afterwards) to get the final shape.
Disclosure: The slotting and welding wasn't a great idea since I did have one of the welds partly break and had to R&R it once. It's much stronger if you have access to a proper bender+shoes.
I knew this might happen beforehand so I don't need anyone to repeat it to me.
Axle side is a 3/16" U ( made out of 5 separate pieces -- 2 of the pieces were too short and I had to add material.) with 1/8" bits for the remainder.
It's a crapload of work and I really wouldn't want to have to build another one from scratch but hey, it's your sanity.
Since the initial fabrication, I have shortened the adjustable part of the chassis side slightly. It was too low and was hitting pavement going over bumpy patches.
ps: waiting for these pictures to float over to c-c.com so the design can get ripped apart.
Oh yea, I used all grade 8 hardware (Bolts, nuts and washers). I didn't have easy access to grade 8 fasteners so I bought the best I could from a local industrial supply house.
MM instructions and people's install pics were very handy.