Just pulling the interior panel off the '90 and peeling the plastic down. Yea, pretty sure '94 was the first year they added the bars, good deal.
Little more time on it tonight before it got too dark, pulled the front section of the driver's door bar out and test fit it, also works. No sheet metal in there so just a matter of drilling out the spot welds. When I put them in the '90 I'll drill holes in more or less the same spot and plug weld them, then paint exterior and rust proof interior -
Ultimate oil undercoating guide (DIY Waxoyl).
Here's a shot of the rear section of bar in place in the '90 with the anti-jimmy plate pried back
Front section on the ground
Front section in place
Both bar sections dry fit and the overlap
Amount that will need to be trimmed 1/2"
Bar OD 31.94mm
ID, after deburring 27.97mm. There is a weld seam so will need smaller than that for interior tube
As I think about this, I'll probably also shoot some epoxy from one of those 10oz self mixing tubes over the front and rear contact points to lock everything together more, after plug welding. It seems like I'd get more strength epoxying bar to the door skin also but everything I can find says to use non-structural foam to attach skin to anti-intrusion bar so I'll prob stick to that again, same way it came off. Going to try to find a shortish section of tube to go inside existing, welded to splice them, and a longer section, close to the longest section of bar I cut in half to sleeve the outside for extra strength, assuming there's room between the window. Need power to this thing to check that. After the swap is finished... Now to pull the rest of these bars and get the engine going.
Sliders later also and I've been toying with a design for bolt-on triangular bracing up front to prevent cabin collapse in a head-on, that earned it the lousy front crash rating in 1990, but not sure that will actually fit. More on that later maybe.